How Much Does it Cost to Re-Gelcoat a Boat?

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Last Updated on August 23, 2024 by Paul Clayton

How Much Does it Cost to Re-Gelcoat a Boat?

The cost to re-gelcoat a boat is a common query for boat owners who want to maintain their vessel’s lifespan and aesthetic appeal. Boat owners need to get a detailed estimate from a reliable service provider to determine the anticipated cost accurately.

• Size impacts costs; larger boats require more materials.
• A 15-foot boat might cost $500-$1000, and a 40-foot yacht might cost $5000+.
• The current condition of the boat affects overall costs.
• Deep scratches or damage increase the re-gel coating expenses.
• Premium gel coats with superior features are more expensive.
• DIY reduces labor costs but demands time and expertise.

Do you miss the days when you showed off your shiny brand-new boat? Every time you docked it, you probably felt proud of your watercraft’s lustrous exterior, making it stand out among the other boats.

But that was years ago, right? And your ship has aged now. However, the good news is that you can make your fishing companion look shiny again. How? Please give her a makeover by removing the faded gel coat from the hull and replacing it with a new one.

In short, re-gelcoat the vessel and make her look ten years younger. Choosing a different gel coat color can give it a new look. Now, you must think, how much will you spend in the process?

The cost to re-gel coat a boat is not too high, considering how beneficial gel coats are for your ship’s maintenance. So, are you interested in the beautification process? Read on.

What Is a Gelcoat?

A gel coat is a thermosetting polymer with either an epoxy or polyester resin base. It is applied to fiberglass surfaces for a glossy, high-quality finish.

Almost all watercraft manufactured using fiberglass have an outer layer of gel coating, particularly the hulls.

In a liquid form, this polymer is applied in a uniform thin layer (0.02 – 0.03 inches) on top of the fiberglass, dries to harden, and forms a shell-like casing around the boat.

It often contains pigments and is available in many custom colors to make the boat’s exterior look appealing.

Why Is Gelcoat Important?

There is a reason why gel coats are applied to all marine crafts and boats with fiberglass hulls at their manufacturing time. You might be surprised that fiberglass hulls are not entirely impervious to water and can absorb water to form blisters.

Though fiberglass is used in boats for durability, it is susceptible to damage and becomes weak ( fiber blooming) due to ultraviolet rays in sunlight. This is where a gel coat comes in handy.

It is not just a coloring agent that glistens up the surfaces it is applied to, but also has unique protective properties. The gel coat prevents fiberglass from ultraviolet degradation, hydrolysis, and other harmful chemical reactions.

Is Gelcoat Better than Paint?

You might get tempted to repaint your vessel’s hull with high-quality anti-fouling/bottom paint. Although repainting seems quicker, cheaper, and less laborious, it is unsuitable for protective effects or durability.

Paints are prone to chipping and provide almost no protection to the hulls from harmful chemical reactions. Paints last for only two years and are difficult to maintain. Furthermore, bottom paints contain copper, which is highly hazardous.

Copper tends to mix in the water as you sail, poisoning the creatures below. It also harms your health, and care should be taken not to let the paint get into your skin and eyes.

In comparison, Gelcoat is a safer option as it does not chip, is not harmful, does not contain copper, and is not prone to dissolve in water.

How Long Does a Gelcoat Last?

Did you know gel coats can keep your boat looking glamorous for up to 10  or more years? Give the old-looking hull surface a new gel coat layer and forget worrying about it, as it will last you more than a decade, provided you give it the proper maintenance.

All it takes is to apply a wax layer every three to four months, wash the hull with marine boat soaps, and store the ship in cool, dry places away from sunlight.

Using good quality carnauba wax, sealant, and fiberglass stain remover will often save the hassle of a labor-intensive Gelcoat job.

Average Cost Estimate to Re-Gelcoat a Boat

There is no exact estimate of the cost to re-gelcoat a boat since all boats are of different sizes and display varying amounts of damage that need additional steps of re-gelcoating.

Even if you plan to only go for a color change on a new, undamaged boat, it still needs to go through specific steps.

So, if you are getting professional, they might charge you around $300 to $500 per foot for the entire process. One-third of the cost is the materials, and the remainder is the labor cost.

For example, with a 16-foot craft, prepare to spend around $8000 on re-gel coating. However, this is a rough estimate, and prices can vary significantly.

Factors Affecting the Cost of Re-Gelcoat a Boat

Re-gel coating is pretty simple if the old gel coat needs no repair. It just requires a few cleaning steps, sanding, and a final application of a gel coat and wax.

However, the scenario changes if your gel coat is damaged. The following are the two main factors that affect the total cost to re-gelcoat a boat.

Crazing

If a gel-coated vessel’s surface resembles a cracked eggshell, the boat is undergoing ‘crazing.’ Crazing is a common issue that can damage the vessels deeply if left untreated.

Labor and material costs increase due to crazing, as a considerable amount of sanding and grinding is needed to fix the cracks first. Then, some heavy-duty epoxy is used for filling and patching before the final finish coat is applied.

Blistering

Gel coats suffering from blistering need special attention, too. It needs grinding to even out the affected area. Then, epoxy laminates and fillers are used for filling and fairing. Repairing blisters can add a great deal to the cost of re-gel coating.

DIY Re-Gel Coating: Save Your Money

Instead of taking the watercraft to a yard, leaving it there for the work, and investing a considerable sum of money in laboring, you could try doing it all by yourself.

You will save pennies this way and enjoy giving the vessel a makeover according to your taste.

Here is a list of items you will need for a 25-foot boat(to cover an area from waterline to gunwale), along with their average costs, followed by a step-by-step guide to re-gel coating your ship the DIY way.

Material List

• 3M tapes – $8
• UV tapes – $10
• Masking tapes – $5
• Dykem steel blue dye – $18
• Sandpapers –  $18
• Brushable Gel Coat – $100
• Sander machine – $35
• Buffer – $20

Additional Material

• MEKP catalyst – $16
• Wax additives – $20
• PVA surfacing agent for gel coats – $45
• Pigments for gel coat – $17

Safety Equipment

• Tyvek Suit – $8
• Gloves – $12
• Respirator mask – $19

The list totals around $350. So, once you have all the equipment, you can move on to the procedure.

Cleaning

Start by cleaning the hull with soap and water. Then wash it off properly with water, leaving no soap residue behind.

Prepping

Use tapes and masking papers to cover surfaces adjacent to your work area. Cover and protect other parts of the boat by tarping them. And make sure you put on your safety equipment.

Inspecting

The next step involves examining the surface. Check the gel coat for any nicks, scratches, or cracks. If present, sand the area using 40 grit and then fill them up using epoxy putty. But you can move on to the next step if there are none.

Sanding

This is the most critical and highly laborious step in the gel coating process. Start by applying the steel blue dye on the entire surface and sand with 150-grit sandpaper.

When you see the blue stain no more, it means you have smoothed the area enough (this will take a while; remember you don’t have to do it all in one day).

Once you have completed the sanding, you must clean off the surface with acetone and apply the gel coat quickly, as you don’t want any dust particles to accumulate on the cleaned surface area.

Application of Gel Coat

Apply two layers of gel coat using a four-inch-wide brush that is neither too soft nor too hard. Apply it evenly at a thickness of 18-20 mils (use a mil gauge for measuring). Let it cure overnight, and you will be ready to wet sand and buff it the next day.

Use 300 or 400-grit wet sandpaper for the initial damp sanding. Move on to 600 and finally to 800 grit sandpaper. Then, use a buffer covering a 4×4 foot area at a time.

Waxing

Finish off by applying a layer of machine glaze followed by two coats of wax.

In the end, after all the hard work, you have a glossy, lustrous boat that looks professionally re-gel coated in a budget-friendly way.

How Do you Maintain a Gel coat on a Boat?

Maintaining the gel coat on a boat is a crucial aspect of boat upkeep. First, It is essential to remove all surface dirt. This can be accomplished by washing your hull and topsides with marine boat soap diluted in water.

The second step involves stain removal. Use a quality marine cleaner to gently lift and remove stains without damaging the gel coat.

The third step is removing oxidation to restore the shine of the gel coat. A good-quality oxidation remover should be used for this process. Finally, protect the newly restored shine with a layer of wax.

Final Words

The cost to re-gelcoat a boat varies significantly based on several factors. The size of the boat is one of the primary determinants, with larger boats requiring more materials and, therefore, incurring higher costs.

For instance, while a 15-foot boat may only cost between $500 and $1000 to re-gelcoat, a 40-foot yacht could cost upwards of $ 5,000. Beyond size, the boat’s current condition determines the overall cost.

Boats with deep scratches or damage will require more extensive work, thus increasing the re-gelcoating expenses. Selecting premium gel coats with superior features will also add to the total cost.

However, DIY can significantly reduce labor costs if one has the necessary time and expertise. However, it’s essential to ensure a quality job to maintain the boat’s lifespan and performance.

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