Lesson 1Fairing and finishing: grinding sequence, fairing compound selection, fibreglass veil/surfacing layers, gelcoat application methods (spray, brush, paste), polishing and colour match tipsThis section covers grinding and fairing sequences, choosing fairing compounds, using veil or surfacing fabrics, spraying or brushing gelcoat, and polishing and colour matching so repairs blend invisibly with original finishes.
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 reassemblyThis section explains how to reinstall through-hulls and hardware, choose bedding compounds, apply sealant correctly, torque fasteners in sequence, and verify watertight, strain-free reintegration of repaired components.
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 contaminationThis section explains how to secure the boat, strip or protect nearby hardware, clean and degrease the work zone, and control dust and overspray so the laminate stays uncontaminated and ready for reliable 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 strategiesHere you will assess damage to stringers, bulkheads, and local reinforcements, then plan scarf joints, core replacements, tabbing schedules, bonded inserts, and fastener layouts that restore stiffness and load paths 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 patchYou will learn how to design a laminate schedule, choose fabrics and orientations, set overlaps and stagger joints, calculate typical ply counts, and execute reliable wet-out for a strong, fair midship hull patch or panel repair.
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 metersThis section covers diagnosing moisture in skins and cores, using heat, airflow, vacuum, and desiccants to dry structures, and confirming dryness with moisture meters and core samples before committing to laminate rebuilding.
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 exothermYou will learn how temperature, humidity, and film thickness affect cure, how to use heaters, tents, accelerators, or retarders, monitor exotherm, and apply post-cure methods that maximise strength and dimensional stability.
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 minimising blisters or adhesion failuresHere you will learn how to choose polyester, vinylester, or epoxy for specific repairs, evaluate compatibility with existing laminates, use tie coats and barriers, and reduce risks of osmotic blistering or bond failure over time.
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 rationaleThis section details how to open damaged laminate safely, choose scarf or V-groove geometry, set bevel ratios, avoid undercutting sound glass, and prepare a clean, textured bonding surface ready for structural rebuilding.
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
