Best way to patch fiberglass?

OP...there are probably a few YouTube howto available for the step by step procedures.

fly-boy wrote:
I would repair it with glass but if you are concerned about doing it I have an easy fix-

Cut out around the damaged area and fill it with expandable foam so you keep H2O out. Sand it down as flat as you can.

Then buy a 4x8 foot piece of 0.020 matte aluminum sheet with an adhesive laminate on it. Have the metal cut to run entirely across the ramp and cover the hole. It should look just fine and you will be good to go!

If you need the aluminum- PM me. I can cut and ship a sheet with the adhesive already applied so all you have to do is peel and stick.

I'm surprised you didn't mention Sun Cure: http://www.amazon.com/Sun-Cure

That is exactly what I would have used for that repair and yes, it would have stayed water tight and a permanent fix. I actually carry a tube of it in my trailer just in case.

I have done WAY to many fiberglass repairs and know this stuff works.

artguys wrote:
Go to West Marine , Boat US or the like. Don't buy the more expensive Epoxy fix systems...lots more expensive and it adds a extra layer of steps. Anything epoxy requires a final finish to protect from UV issues, rather choose a polyester resin fix solution, and add a coloring agent...hence no need for the extra layers of finish,as polyester resins alone can stand up to uv issues. Get a patch kit with fiber mat then buy the resin and catalyst. Leave damaged area as is and simply fill in the void with available material such as cardboard etc. The final finish doesn't require a gel coat just a series of abrasives to finish with a 2000 wet dry and polish.

Help me follow along. Are you saying to patch any fiberglass with polyester, no matter what the original substrate is made from?

And, do you know what this particular door is made from?

Thanks in advance

Go to West Marine , Boat US or the like. Don't buy the more expensive Epoxy fix systems...lots more expensive and it adds a extra layer of steps. Anything epoxy requires a final finish to protect from UV issues, rather choose a polyester resin fix solution, and add a coloring agent...hence no need for the extra layers of finish,as polyester resins alone can stand up to uv issues. Get a patch kit with fiber mat then buy the resin and catalyst. Leave damaged area as is and simply fill in the void with available material such as cardboard etc. The final finish doesn't require a gel coat just a series of abrasives to finish with a 2000 wet dry and polish.

I had a hole like that when my wife backed me I up with a popup. She was only looking at one side and failed to notice the woodpile boom. Insurance called $1400 repair. The shop removed rear panel and installed new part. I traded with damage, cursed out wife, cut 4 trees down, and do it solo!

I'd repaint the whole tailgate, you won't match it

Frankandbeans wrote:
Wow...ok. So many options to choose from regarding what kind of fiberglass repair kit to use!

How about step 1 - What do you guys think of using the expanda foam as a way of having something for the fiber glass patch to stick to? I will take a picture of what I'm working with tonight so everyone can see what I'm trying to accomplish.

I AM going to fix this myself. I'm seeing a lot of similarities in RV's and sport bikes - it doesn't take much to total out these things. To be honest, it's not blue booking for a whole lot, and if I made an insurance claim to fix this and some other minor things (That aren't that big of a deal, but labor prices are insane), I'm willing to bet they could total it. I just want it to be water proof and as close to smooth as I can get it. I'll paint it with the classiest rattle can I can find, and call it good.

It's not that hard, I really don't care what anybody says. I've repaired mach3+ aircraft panels and they're still flying, or in a museum now hahaha.

I would say no on the expanding foam. Next, I would find out for sure what kind of resin was used to make the door. Next, there is a product for this kind of repair. It's like the above poster said, bondo type material, it's green and does have the fiber in it. It is the strongest I've found in 39 years. A good auto paint sore will have it, it's Evercoat Kitty Hair. Stronger than the Hulk (hahaha), really it is good.

Sand the door and surrounding area with some 36-60 grit to get ready. Mix up the kitty hair, and put it into the hole, as long as it's not a gapping hole that has no solids in it all the way around the hole. I mean there is enough material to keep the kitty hair from falling inside the door, and too deep. (kinda hard to tell with words and no pictures)

Be careful to not over fill, this kitty hair is a big bear to sand smooth. Fill it enough, but not over fill. Use an airfile to sand it down (auto body shop for about $100 or harbour freight for $50 maybe). For the last thin coat, regular body filler over 36-60 grit scratch marks will be ok, it'll stick.

Get it smooth, and spray some primer over the repair. Use a very flat board, plexiglass, t angle or any tool that is very flat and can put a piece of sand paper on it. If you do it by hand, you'll have all kinds of divets in it.

It should be smooth and ready to paint at this point.

BBTank

Update: It's been patched.

Now the question is, which way to go about painting? Here's my dilemma: It's a 2005, it cleans up well, but it's not brand new either. Do I pay a shop to paint/gel coat it, knowing it's going to be near impossible to match the white anyways? Do I do a hack job with spray paint, knowing the white won't match perfect either, and just cover up with a sticker?

I would repair it with glass but if you are concerned about doing it I have an easy fix-

Cut out around the damaged area and fill it with expandable foam so you keep H2O out. Sand it down as flat as you can.

Then buy a 4x8 foot piece of 0.020 matte aluminum sheet with an adhesive laminate on it. Have the metal cut to run entirely across the ramp and cover the hole. It should look just fine and you will be good to go!

If you need the aluminum- PM me. I can cut and ship a sheet with the adhesive already applied so all you have to do is peel and stick.

WoW that's some work there! So if I were to repair it. I would mask off the area and make cut it out a square box using a router of a skill saw. Then you would need to fill the void with something so it would fall down. I would use hard Styrofoam as a backing then repair it using fiberglass as mention above. Or take it to a boat repair shop.