Lesson 1Fairing and finishing: grinding sequence, fairing compound selection, fiberglass veil/surfacing layers, gelcoat application methods (spray, brush, paste), polishing and color match tipsCovers grinding order, picking fairing mixes, using veils or surface cloths, spraying or brushing gelcoat, and polishing plus colour matching so fixes blend right in.
Progressive grinding and surface refinementSelecting and mixing fairing compoundsUsing veil cloth and surfacing layersGelcoat application, thickness, and cure checksSanding, polishing, and color matching repairsLesson 2Sealing and reintegration: through-hull fittings, bedding practices, sealant selection and torque sequences for reassemblyShows reinstalling through-hulls and gear, picking bedding, applying sealant proper, torquing bolts in order, and checking watertight, no-strain refit of fixed parts.
Evaluating and sizing through-hull fittingsChoosing polysulfide, polyurethane, or siliconeSurface prep for reliable bedding adhesionSealant application and torque sequencesLeak checks and post-launch inspectionsLesson 3Initial preparation and isolation: securing the vessel, removing fittings, masking, cleaning the repair area and preventing contaminationExplains securing the boat, stripping or shielding nearby gear, cleaning and degreasing the spot, controlling dust and spray so laminate stays clean for good bonding.
Stabilizing and shoring the vessel safelyRemoving hardware, trim, and nearby fittingsMasking strategies for decks, hull, and hardwareDegreasing, detergent washing, and solvent wipesDust, overspray, and airborne contaminant controlLesson 4Internal structural repairs: assessing and repairing stringers, bulkheads and local reinforcements — scarfing, tabbing, bonded inserts and fastener strategiesAssess harm to stringers, bulkheads, local strengtheners, then plan scarfs, core swaps, tabbing, bonded bits, fastener setups to bring back stiffness and load lines safely.
Inspecting stringers, floors, and bulkheadsRemoving rotten core and rebuilding websScarf joints and structural tabbing detailsBonded inserts and backing plate designFastener selection, spacing, and sealingLesson 5Laminate rebuild strategy: layer schedule, fabric orientation (biaxial/unidirectional placement), overlap rules, wet-out procedures and typical ply counts for midship hull patchLearn designing laminate plans, picking cloths and directions, overlaps and joint staggers, usual ply numbers, and solid wet-out for strong, smooth midship hull patches.
Reading and recreating original laminate scheduleChoosing biaxial, woven, and unidirectional fabricsOverlap, taper, and edge staggering rulesHand layup and wet-out best practicesTypical ply counts for midship hull patchesLesson 6Drying and decontamination: techniques to remove moisture from laminate and core (heat, desiccants, vacuum) and verifying dryness with metersCovers spotting moisture in skins/cores, using heat, air, vacuum, driers to dry out, and confirming with meters and samples before laminate rebuild.
Locating wet laminate and core zonesHeat lamps, heaters, and controlled airflowVacuum bag and desiccant drying techniquesSalt, oil, and contaminant removal methodsUsing moisture meters and confirming drynessLesson 7Controlling cure conditions: temperature, humidity, use of accelerators or retarders, post-cure methods and monitoring exothermLearn how temp, humidity, thickness affect cure, using heaters, covers, speeders/slowers, watching heat buildup, post-cure for top strength and shape hold.
Resin pot life, gel time, and cure stagesTemperature and humidity control methodsManaging exotherm and thick section buildsUse of accelerators, retarders, and promotersPost-cure schedules for strength and print controlLesson 8Resin selection and compatibility handling: bridging existing polyester with vinylester/epoxy, using barrier coats, and minimizing blisters or adhesion failuresPick polyester, vinylester, or epoxy for jobs, check match with old laminates, use tie coats/barriers, cut risks of blisters or bond fails long-term.
Identifying existing resin and laminate typeWhen to choose polyester, vinylester, or epoxyTie coats and barrier coats between dissimilar resinsPreventing osmotic blistering in repaired areasAdhesion testing and troubleshooting bond issuesLesson 9Opening and preparing the damaged area: grinding patterns (scarf, V-groove), bevel angles, how much laminate to remove and rationaleDetails safe opening of bad laminate, scarf or V-groove shapes, bevel ratios, not cutting good glass, prepping clean textured bond face for rebuild.
Mapping crack paths and hidden damageChoosing scarf versus V-groove approachesBevel ratios for hull, deck, and structural areasGrinding tools, discs, and dust collectionFeathering edges and final surface profiling
