Sea-doo 2003 GTI LE RFI, Shop Manual

Page: 729 / 779

Section 16 HULL/BODY
Subsection 02 (ADJUSTMENT AND REPAIR)
16-02-44
SMR2003-046_16_02A.FM
Inside
For the interior repair, you can grind more. This will
allow for more fiberglass material which will
strengthen the area. If the fracture opening is too
large after surface preparation, you may need a
backing support to cover the opening. Cut alternat-
ing pieces of fiberglass mat and cloth in overlap-
ping sizes.
PATCHING THE REPAIR AREA
Outside
The outside should be done first. Wipe clean the
area with acetone on a cloth, then mask off area.
For a small crack use an epoxy filler in the same
way you would use gelcoat repair putty. When lay-
ing up a larger area you will use mat, cloth and
fiberglass resin and catalyst. Use a clean container
to mix the resin, mix only what you will need. Fol-
low the recommended catalyst ratio.
Using a clean paintbrush, brush the mixed resin on
the surface. Place the smallest piece of mat over
the fracture and then wet out the mat. Follow with
the remaining pieces of mat and final layer of
cloth. While wetting the pieces make sure you
work the air bubbles out and saturate all the pieces
evenly. Try to work quickly, you may only have 15
or 20 minutes. You may clean the brush with ace-
tone.
Wait until the repair has hardened before moving
on to the interior repair. If the size of the opening
is too large for the pieces to maintain the proper
shape, you will have to use a backing support. It is
a shaped piece of cardboard that fits flush to the
interior surface and has a plastic layer on the repair
side. It is held in place by tape or a support.
Inside
Wipe down the area with acetone on a cloth. Ap-
ply the same procedure as for outside repair when
laminating the alternating pieces of fiberglass ma-
terial. If a backing support was used, remove it
before starting the repair. After the area has hard-
ened, remove sharp edges of material from sur-
face. If required paint the surface.
SANDING
Outside
This surface will have to be prepared for applica-
tion of gelcoat. The size of the area will determine
the gelcoating procedure to be used. Refer to the
repair procedure for minor gelcoat fractures.
BUFFING AND WAXING
Refer to the buffing and waxing for Minor Gelcoat
Fractures .
TOOLS AND MATERIALS LIST
Tools
– safety glasses
– air mask
– white cloths
– sanding block
– putty knife
– plastic film
– stirring stick
– cover sheets (for Sea-Doo)
– scissors
– buffing pad
– heavy-duty polisher
– power sander
– paint brush
– plastic container (mixing)
– spray gun
– plastic squeegee.
Materials
– fiberglass mat
– fiberglass cloth
– polyester resin
– cardboard
– masking tape
– sandpaper (100-grit, 220-grit, 320-grit, 400-grit,
600-grit, 1000-grit)
– 24-grit sanding disks
– gelcoat putty
– liquid gelcoat
– acetone
– cabosil
– epoxy filler
– medium compound (white)
– fine compound (white)
– wax.
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