How Much Does It Cost to Re-Gelcoat a Boat? All You Need to Know!

If your boat is looking a little tired, you might think a fresh coat of gel coat or paint will spruce it up a bit. But re-gel coating a boat is no small job—it usually involves spraying the finish after removing all of the fixtures and preparing and fairing the surface.

The good news is that many boats can be restored to their factory-new shine by simply compounding and waxing the existing gel coat.

But if the relatively soft surface has deteriorated and worn away, you’ll need to either paint or re-Gelcoat the boat. So how much does it cost to gelcoat a boat? The answer probably won’t surprise you—quite a lot!

Table of Contents

• Gel Coat Repair Cost
  • DIY Gel Coat Repair
  • Professional Gel Coat Repair
• What Is Gel Coat?
  • Why Is Boat Gel Coat Important?
• Don’t Confuse Gel Coat With Bottom Paint!
• How Is Gelcoat Different Than Topside Paint?
• Gel Coat vs Boat Paint
• How to Know You Need Gel Coat Repair
  • 1. Visual Inspection
  • 2. Texture Changes
  • 3. Water Damage
  • 4. Poor Performance
  • 5. Routine Maintenance
• Can You DIY Restoring Gelcoat?
  • DIY vs Professional
• How to Restore Tired Gelcoat
• When Is There No Other Option Than Re-Gel Coating a Boat?
• Painting Instead of Re-Gelcoating a Boat
• Be Finished With the Finish
• FAQs (Frequently Asked Questions) 

Gel Coat Repair Cost

The cost of gel coat repair can vary widely depending on several factors, including the extent of the damage, the location of the repair (e.g., on the hull, deck, or elsewhere), the color and type of gel coat needed, and whether you’re doing the repair yourself or hiring a professional.

DIY Gel Coat Repair

• $40 to $150+, depending on the scale of the repair and the tools you already have.

Professional Gel Coat Repair

• Small Repairs: For minor scratches or chips, professional repair costs can start from $100 to $300.
• Moderate Repairs: For larger areas of damage or more significant cosmetic issues, costs can range from $300 to $800.
• Extensive Repairs: Major repairs, such as large cracks, significant oxidation, or structural issues underneath the gel coat, can cost $800 to $2,000 or more, depending on the complexity and labor involved.

What Is Gel Coat?

Gel coat is the outer surface that you see on a fiberglass boat. It is usually white, although sometimes it is colored on the sides of a boat’s hull, and some manufacturers use a beige color instead of bright white. Gel coat is a smooth, waxy surface that protects the fiberglass underneath from UV sun damage and water.

Gel coat is a two-part polyester resin that is applied inside the mold when the manufacturer makes the boat. As a result, it makes fiberglass surfaces perfectly smooth, and everything on the boat is attached on top to it.

Gel coat lasts a very long time, but it doesn’t last forever. The sun eats away at it over the years, and if not properly cared for, it can start to absorb dirt, grime, and salt. It can be restored by compounding, but that will eventually wear down the thickness of the gel coat until not much is left.

When the gel coat gets thin, and the fiberglass is showing through, something will have to be done to protect the boat. At that point, you can either re-gelcoat the boat, or you can have it painted.

Why Is Boat Gel Coat Important?

Boat gel coat plays a crucial role in protecting the vessel, enhancing its appearance, and extending its lifespan, making it an essential component in boat construction and maintenance.

1. Protection: Gel coat is a thick, protective layer applied to the outer surface of a boat’s hull and deck. It shields the underlying fiberglass from damage caused by UV rays, saltwater, and other environmental factors, preventing the fiberglass from deteriorating over time.
2. Aesthetics: Gel coat provides a smooth, glossy finish to the boat’s exterior, enhancing its appearance. It is available in various colors, allowing boat owners to customize their vessel’s look.
3. Durability: A well-maintained gel coat can last for many years, extending the life of the boat and helping to maintain its value.
4. Water resistance: Gel coat creates a waterproof barrier, preventing moisture from penetrating the fiberglass and causing damage like blistering or delamination.
5. Easier maintenance: A smooth gel coat surface is easier to clean and maintain compared to raw fiberglass. It helps prevent the buildup of dirt, grime, and marine growth.
6. Improved hydrodynamics: A smooth, even gel coat surface can improve a boat’s hydrodynamics, reducing drag and increasing fuel efficiency.
7. Repairable: If the gel coat becomes scratched or damaged, it can often be repaired without the need to replace the entire fiberglass structure, saving time and money.

Don’t Confuse Gel Coat With Bottom Paint!

One common misconception is that gel coat is waterproof and will protect the hull of a boat stored in the water. Unfortunately, this is not the case.

Boats left in the water, like liveaboard sailboats or powerboats, need to have several protective coatings applied to their bottoms. They first need a barrier coat, which is completely waterproof and keeps water out of the fiberglass boat. When water gets inside the laminate, it can cause osmotic blistering.

Secondly, a coat of bottom paint must be applied to reduce the growth of marine life and algae on the boat’s bottom. Depending on the temperature and nutrient levels in the water, a boat’s bottom can get severely fouled in as little as a month. Growth on the bottom of a boat causes increased drag and resistance, which will slow you down and cause your engine to overheat. Growth in propellers and running gear can significantly reduce their effectiveness.

Even with good anti-fouling bottom paint, boat bottoms need to be cleaned regularly by a diver to knock off all that nasty growth. The bottom paint prevents some growth and makes the bottom of the boat easy to clean. Allowing bare gelcoat to become fouled with growth will be very difficult to clean off and could permanently damage the boat.

The only boats that can get away without bottom paint are those stored on trailers or lifts out of the water and washed clean after every outing.

How Is Gelcoat Different Than Topside Paint?

Wooden boats and some fiberglass boats have paint instead of gelcoat. Compared to paint finishes, gel coat is higher gloss and much harder. While it can be scratched and scuffed, it can easily last 20 or 30 years if well cared for. Most paint jobs struggle to last ten years, and many last less than that.

Gelcoat is a thicker, three-dimensional coating compared to the thin applications of paint. That means that if you scratch or gouge gelcoat, you can usually patch it will a gelcoat repair kit.

The big problem with making minor repairs to the gelcoat is getting it to look right. Gelcoat fades over time, so new patches must be color-matched to blend in perfectly. The readily-available gelcoat kits are usually available in buff white and white. You can also get color kits and mix your hue for colored hulls.

Professionals have all the tools and colors down to spray repairs and blend them in with the existing gelcoat. When they’re done, they’ll look like new.

While the project isn’t beyond the abilities of the average DIY boat owner, most people struggle to get the gelcoat to look just right. There’s an art to it, and it’s one of the few jobs where hiring a professional will consistently provide you with better results than you can do on your own.

Gel Coat vs Boat Paint

Gel coat is best suited for new fiberglass boats or for owners willing to invest in professional maintenance to keep their boats looking shiny and new. Boat paint is more versatile and user-friendly, suitable for a variety of surfaces and applications, including DIY projects.

	Gel Coat	Boat Paint
Composition	Resin-based, used on fiberglass boats	Varies (one-part polyurethane, two-part polyurethane, enamel), used on various materials
Durability	Very durable, resistant to water, chemicals, UV rays. Can become chalky over time	Excellent durability, especially two-part polyurethanes; resistant to abrasion, chemicals, UV rays
Maintenance	More challenging to repair, requires polishing and waxing to maintain gloss	Generally requires less maintenance, simpler repairs, and touch-ups
Application	Applied during manufacturing; repairing/recoating needs professional skills	Can be applied by both professionals and amateurs with the right equipment; allows for color changes
Aesthetics	High-gloss finish, harder to change color or repair	Wide range of colors and finishes (matte, satin, high gloss)
Cost	Repairs can be costly; part of initial manufacturing process	Potentially more frequent reapplication but more straightforward and less expensive maintenance
Performance	Offers good protection against marine environment; issues with oxidation	Good protection, choice depends on specific needs and preferences

How to Know You Need Gel Coat Repair

Here are signs to look out for:

1. Visual Inspection

• Cracks and Chips: Even small cracks or chips can lead to bigger problems, such as water infiltration into the fiberglass.
• Discoloration or Fading: Prolonged exposure to the sun can cause the gel coat to fade or become discolored, indicating it may need repair or restoration.
• Chalking: If the gel coat surface feels powdery or leaves a chalky residue when touched, it’s a sign of oxidation, which requires attention.

2. Texture Changes

• Roughness: The gel coat should be smooth to the touch. Rough patches might indicate damage from impacts, abrasion, or environmental factors.
• Blisters or Bubbles: These can indicate osmotic blistering, a condition where water has penetrated the gel coat and started to break down the fiberglass beneath.

3. Water Damage

• Soft Spots: Areas of the hull that feel soft or spongy when pressed can be a sign of water damage underneath the gel coat, indicating a need for repair not just to the gel coat but possibly to the underlying fiberglass.

4. Poor Performance

• Increased Drag: Noticeable changes in the boat’s performance or efficiency might be due to the deterioration of the hull’s surface, affecting hydrodynamics.

5. Routine Maintenance

• After a Collision or Grounding: Any incident that might have caused damage to the hull should prompt a thorough inspection for potential gel coat damage.
• Regular Maintenance Checks: Even in the absence of obvious damage, regular maintenance checks can uncover early signs of wear and tear that require gel coat repair.

Can You DIY Restoring Gelcoat?

Yes, it is possible to apply gel coat to a boat yourself, but it is a process that requires careful preparation, the right tools, and some skill. Here’s a general overview of the steps involved in DIY gel coating:

1. Preparation: Clean the surface thoroughly, remove any old, damaged gel coat, and make necessary repairs to the fiberglass. Sand the area to create a smooth, even surface for the new gel coat.
2. Masking: Tape off and cover any areas you don’t want to be gel coated, such as hardware, fittings, or trim.
3. Mixing: Mix the gel coat with the appropriate catalyst according to the manufacturer’s instructions. Be sure to use the correct ratio and mix thoroughly.
4. Application: Apply the gel coat using a spray gun, brush, or roller, depending on the size of the area and the desired finish. Multiple thin coats are better than one thick coat.
5. Curing: Allow the gel coat to cure according to the manufacturer’s guidelines. This process can take several hours to a few days, depending on temperature and humidity.
6. Sanding: Once cured, sand the gel coat to remove any imperfections and create a smooth finish.
7. Polishing: Buff and polish the gel coat to achieve a high-gloss finish.

DIY vs Professional

Given the wide range of potential costs, it’s advisable to get multiple quotes from professional repair services if you decide not to undertake the repair yourself. This will give you a better idea of the expected costs and help you budget for the repair.

	DIY Gel Coating	Professional Gel Coating
Cost	Less expensive, only materials and tools needed	More expensive, paying for time, expertise, and materials
Flexibility	Control over timing, work at own pace	Less flexibility, dependent on professional’s schedule
Learning	Opportunity to learn new skills and gain experience	No direct learning opportunity
Time	Time-consuming, especially for beginners or large areas	Time-saving, completed more efficiently and quickly
Quality	May not be as smooth, even, or durable, especially if inexperienced	Typically results in a smoother, more even, and longer-lasting finish
Equipment	Limited to personal tools and equipment	Access to high-quality, professional tools and equipment
Expertise	Dependent on individual’s skills and knowledge	Professional knowledge, skills, and experience ensure high-quality results

How to Restore Tired Gelcoat

The first sign that the gel coat on your boat is beginning to fade is when it becomes chalky and has a matte finish. If water no longer beads up, all the wax is gone, and the surface is oxidizing. The sooner you catch this, the longer you can keep your gelcoat looking new.

Wax is crucial for your boat because it helps keep grime and water out of the gelcoat. Once the wax is gone, gelcoat absorbs quite a bit of gunk. Tired gel coat can even retain enough moisture to start to get moldy and mildewed. It can also begin chipping and breaking like a cracked eggshell.

Start restoring your gel coat by washing the boat thoroughly and removing all stains from the gelcoat, including any mildew spots. Use oxalic acid cleaners for stains. Regular boat soap works great for general cleaning. Rinse it clean with lots of fresh water.

If your rinse water comes off white, that means that the gelcoat has oxidized and is deteriorating. The only way to restore it is to remove the oxidization layer, polish, and wax it. This can be a lengthy process, but it can take a tired-looking boat and make it gleam like it just left the factory.

It’s not possible to do the job without a strong power buffer. The first step is to get the oxidization off with a good quality compound. Different grits are sold for different purposes. If your gelcoat is severely oxidized, you’ll need to use a restoring compound or perhaps wet sand the entire surface.

After compounding has restored the shine, the boat hull is protected with high-quality paste wax. That should hold you over for another six months to a year, but applying wax (and possibly compounding) is an annual task at a minimum.

When Is There No Other Option Than Re-Gel Coating a Boat?

If the gelcoat has worn thin or been damaged by something, there are few choices. If it’s a widespread problem and cannot be remedied by localized repairs or spraying, re-gel coating a boat is the only option to get it back to its factory finish.

Large-scale re-gel coating of an entire boat cost is hard to estimate. It’s nearly always done by professionals with spraying equipment.

Gelcoat cures quickly and is temperamental to temperature and humidity changes. Professionals who deal with it day in and day out are familiar with the exact ratios to use and how to coat the surface just right to avoid sags and drips. Plus, they’ve got spraying equipment that can handle such a thick substance.

How much does it cost to re gelcoat a boat? Nearly all of your costs for a project like this are in labor, but gelcoat isn’t an inexpensive substance. Most boatyards charge $100 per hour or more for skilled painters and fiberglass boat repair workers. The price of labor varies dramatically depending on where you are getting the work done. $100 per hour is on the low end, with more yachting centers in the US averaging more like $150.

But before you use that number to start calculating, don’t forget to include the cost of time to prep the surface. The quality of a gelcoat job is mostly preparation. First, deck fittings and fixtures are removed, which is time-consuming. Then the entire area is sanded and faired, with any cracks or imperfections fixed along the way. The actual spraying will only take a few hours, but the preparation can mean weeks spent in the boatyard.

Suffice it to say, on a moderate-sized cruising vessel the average cost is easily $5,000 or much more to re-gelcoat the deck. But, on the other hand, the boat hull sides might be done for less with no fixtures to remove.

It is possible to reduce the cost to re-gelcoat a boat by doing much of the prep work yourself. You can even experiment with rolling and tipping to get a glossy finish without resorting to professional spray equipment.

Painting Instead of Re-Gelcoating a Boat

But when you consider the cost to re-gel coat a boat, many owners decide on painting for their refinishing. Painting is simpler and more economical. Several well-regarded types of marine paint will hold up for years and will look great. They’ll provide even color and a lasting, bright finish. The two most popular brands of professional paints are Awlgrip and Imron.

Another advantage of paint is that it is much easier for the DIY boat owner to do it themselves. A majority of the cost of a paint job is preparation. If you can sand and fair the boat smoothly, chances are you can apply premium topside paint too.

Rolling and tipping is a painting technique resulting in a glossy finish that comes out very close to professional spray application. Yacht finishes are available in either one or two-part solutions. Two-part paints are more difficult to apply and much harder and will last longer.

No matter what sort of finish you choose, it’s best to pick a brand and stick with its system. You do not want any adhesion or compatibility issues to pop up along the way, which can quickly ruin a lot of work and money. Furthermore, you must follow their complete instructions, including drying and curing times and the use of primers and thinners.

One final note about painting over gelcoat however. If you ever want to apply gelcoat in the future, you’ll have to remove all the paint. So generally, most boaters stick with paint once they’ve gone down that road.

Be Finished With the Finish

Re-gel coating a boat ranks up there with the biggest boatyard projects. It’s a lot more complicated than applying a coat of paint, and it’s temperamental stuff that you’ll want to get some practice with. It’s not impossible to DIY Gelcoat projects, but only if experienced with epoxy, resins, and other fiberglass boat projects.

If you’re new to boating and thinking of re-gelcoating your new boat, consult with your local boatyard to pin down the scope of the project and average cost before you dive in.

FAQs (Frequently Asked Questions)