
How to use this kit
Five yards of 6 oz plain weave E-glass with the resin to lay it up. Every kit ships with this same sheet printed and in the box.
What is in the kit
- 5 yd 6 oz woven fiberglass cloth, 50 in wide, folded packabout 62 sq ft
- 1 Resin, your choicegallon Silmar 249 polyester with MEKP, or half-gallon marine epoxy kit
- 6 / 6 Mixing cups, mixing sticks
You supply: a squeegee or laminating roller, chip brushes, gloves, a respirator, sandpaper, and fumed silica or fairing filler for fill coats.
Mixing (check which resin you chose)
| Polyester | 1.5 percent MEKP, 10 drops per ounce |
| Epoxy | 3 parts resin to 1 part hardener |
| Either way | Mix only what you can use in 15 min |
This kit ships with the resin you selected. Polyester uses MEKP by percentage; epoxy uses a fixed volume ratio and never varies. Confirm against the label on your container.
Coverage: 6 oz cloth is light, so either resin choice fully wets out all 5 yards with resin left over for fill coats.
The job, start to finish
Prep the surface
New mold: wax and release it thoroughly. Old laminate: grind off all gloss, gelcoat and contamination back to solid glass, then wipe with acetone. Polyester is a poor secondary bond, so every bit of its grip comes from clean, freshly ground surface.
Cut everything dry
Cut your cloth to size, allowing a few inches of overhang you can trim after cure. Cut all of it before you mix a drop, because once resin is catalyzed you have about 15 minutes and no time to be looking for scissors.
Mix small batches
Catalyze only what you can lay up in 15 minutes, using the chart at left. Stir thoroughly but slowly to avoid whipping in air, and scrape the sides of the cup. Pour it out of the mixing cup as soon as it is mixed: resin left in a deep cup heats up and kicks early.
Wet out
Brush resin on, lay the cloth in, and stipple straight down with the brush until it turns translucent. Do not brush sideways: that drags the fibers out of place. Work wet on wet through your stack rather than waiting for cures between plies.
Fair and topcoat
Once cured, knock down the high spots and fill the weave with resin thickened to a peanut butter consistency with fumed silica. Sand fair through the grits. Laminating resin has no UV protection or wax, so it needs gelcoat or paint over it before it lives outside.
If something goes wrong
Cloth still looks white
It is dry, not wet out. Stipple more resin in until it goes clear or that area has no strength.
Weave still shows after coating
Normal after one coat. It takes two or three fill coats to bury 6 oz weave.
Cloth shifted during layup
Squeegee from the centre outward, never sideways from an edge.
Laminate feels tacky
Normal for polyester laminating resin, which stays tacky on top so the next layer bonds.
Bubbles under the cloth
Work them to the nearest edge with the squeegee while wet, before it gels.
Cloth goes clear when fully wet out, which is how you check for dry spots. Fill coats bury the weave. Gelcoat, paint and varnish are at boatsuppliers.com.