Walker Bay Generation 450, Owners & Safety Manual

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For repairs, parts, or service contact your local dealer or Walker Bay® customer service at:
email: info@walkerbay.com
REPAIRS
In the event of more serious hull damage such as a hole or crack do not use the boat. Contact your dealer.
GELCOAT REPAIR:
Gelcoat may fade or chalk with time or be scratched with use. Here are instructions to repair gelcoat.
Surface scratches can be buffed out of gelcoat with polishing compound. Deep scratches must be filled.
If the gelcoat surrounding a scratch is in good condition then a gelcoat paste from a marine supply store is recommended for
repair.
Gelcoat repair kits include a small quantity of gelcoat paste, hardener, a selection of pigments, mixing sticks and sealing film.
We recommend a flexible plastic spreader. You will need sheets of 150, 220, 400, and 600 grit wet-or-dry sandpaper.
To repair multiple scratches we recommend a small bottle of styrene. Wiping the scratch with styrene prior to filling it partially
reactivates the old gelcoat resulting in a chemical bond between the old and new gelcoat.
Preparing the Scratch
Do not repair a scratch by simply painting over it with gelcoat. For a permanent repair, draw the corner of a scraper or
screwdriver down the scratch to open it into a vee and wipe the open scratch with styrene to reactivate the old gelcoat.
Catalyzing
The hardener for gelcoat is the same for any polyester resin: methyl ethyl ketone peroxide, or MEKP.
Gelcoat resin usually requires 1 to 2 percent of hardener by volume (Follow the gelcoat manufacturer’s instructions).
The mix should not “kick” or start to harden in less than 30 minutes. Ideal hardening time is approximately two hours.
Use caution when adding hardener, too little hardener is better than too much.
Stir and mix the hardener thoroughly.
Spreading Gelcoat Paste
Work the gelcoat paste into the scratch with a flexible plastic spreader. Polyester resin shrinks slightly as it cures so allow the
paste to bulge a little behind the spreader tool when applying. You will sand the patch when it has dried. Scrape or clean any
excess paste outside the patch area.
Covering the Repair
Gelcoat will not fully cure in air. To seal the surface of a scratch repair cover it with a sheet of plastic film. The repair
kit should include sealing film, if not a section of “Ziploc” bag works well as it tends to remain smooth without adhering to the
gelcoat. Tape one edge of the plastic to the surface just beyond the repair, then smooth the plastic onto the gelcoat and tape
down the remaining sides.
Sanding and Polishing
After 24 hours, peel away the plastic. A 6” length of 1” x 2” wood makes a convenient sanding block.
Wrap the block with a quarter sheet of 150 grit paper. Use the end of the block to confine your sanding to the new gelcoat.
Use short strokes. Take care to only sand the patch and not the surrounding surface.
Never do this initial sanding without a block backing the paper.
When the new gelcoat is flush or level with the old gelcoat, put 220 grit wet-or-dry sandpaper on the wood block and wet sand
the repair, this time with your block flat. Use a circular motion and keep water on the sanding area. Feather the repair into the
old gelcoat until you cannot detect a ridge with your fingertips.
Switch to 400 grit wet-or-dry paper without the wood sanding block. Wet sand the surface until the repair area has a uniform
appearance. Repeat this step with 600 grit wet-or dry sand paper.
Dry the area and use rubbing compound to give the gelcoat a high gloss. Buff the repaired area in a circular motion using
heavy pressure to start. Progressively reduce the pressure until the surface becomes glassy.
If the gelcoat shows swirl marks, buff them out with a fine finishing compound.
Finish by applying a fresh coat of wax to the area.