BOMBARDIER SEA-DOO GS 5626 1998, Shop Manual

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Section 12 HULL/BODY
Subsection 02 (ADJUSTMENT AND REPAIR)
12-02-27
HULL AND BODY REPAIR
General
Gelcoat is the smooth and durable cosmetic finish
which coats the fiberglass hull and body of a Sea-
Doo watercraft. It also provides a protective barri-
er against water and sun. It consists of a mixture
of resin, pigment (coloring), fillers, monomers and
catalyst which is sprayed into the mold.
The body and hull of the Sea-Doo are constructed
of chopped fiberglass, saturated with resin. It is
sprayed on the layer of gelcoat along with pieces
of fiberglass mat, cloth and woven rowing which
are added at required areas. This type of construc-
tion is very accommodating for high quality re-
pairs. With patience, the proper techniques and
materials, a damaged area can be restored to an
original finish.
NOTE: Fiberglass repair kit is available through
automotive or marine suppliers. Gelcoat repair kits
are available through regular channel.
Air Bubbles
Possible cause:
– Air pocket trapped between layers of laminate
and gelcoat.
PREPARATION OF SURFACE
Remove all of the damaged gelcoat surrounding
the air bubble with a putty knife or preferably a
carbide grinding tip. Make sure all loose and weak
areas are completely removed. Sand a small area
of the gelcoat surface with 220-grit sandpaper. If
needed, sand the cavity itself. These areas must
have a rough surface to allow the gelcoat putty to
bond properly.
FILLING THE CAVITY
The prepared surface must be cleaned with ace-
tone on a cloth. Use the Bombardier gelcoat repair
kit (P/N 295 500 100). Follow the mixing instruc-
tions in the kit when preparing the gelcoat putty.
Carefully mix the required amount while making
sure there are no air bubbles in the mixture. With
a putty knife, fill the repair area and cover with
plastic film. Curing time may depend on tempera-
ture, amount of putty and percentage of catalyst.
After 2 hours, press lightly on the surface with fin-
gers to test the hardness. When the area be-
comes hard, remove the plastic film.
SANDING
Begin block sanding the patch with 320-grit sand-
paper until you come close to the original surface.
Remove dust with a water soaked cloth and con-
tinue sanding with a 400-grit wet paper. Finish
wet sanding with a 600-grit to remove deeper
scratches. If needed you can wet sand with finer
grit paper such as 1000-grit.
BUFFING AND WAXING
Buff the surface using a heavy duty polisher with
a buffing pad. Make sure the pad is free of dirt or
you may damage the gelcoat. Carefully begin
buffing with a white medium compound. Finish
off using a fine compound. While buffing, pay
close attention to avoid overheating the surface.
Blisters
Possible causes:
– Insert catalyst.
– Improper catalyst/gelcoat ratio.
A blister is a visible bump on the watercraft sur-
face that may not necessarily come right through
the gelcoat layer. In the case of only a few blisters,
follow the same repair procedure as for air bub-
bles. If they are numerous and in close concentra-
tion, spray liquid gelcoat to achieve proper repair.
This procedure is covered in
Minor Gelcoat Frac-
tures .
Minor Gelcoat Fractures
Possible Causes:
– Flexing of fiberglass laminate.
– Gelcoat thickness.
– Direct result of impact.
;
WARNING
Protect skin, wear gloves when in contact
with resin, hardeners and gelcoat. A barrier
skin cream may also be used. Do not expose
area to open flame or lit cigarette. Some of
the materials are flammable. Protect eyes,
wear safety glasses when grinding, sanding
or spraying. Use a dust mask when sanding
or grinding. When spraying wear a respira-
tor or paint mask. Always read warning la-
bels on products.