by Peter McMinn » Wed May 28, 2003 1:14 pm
To fill chips of this kind, I first check to see that the fiber under the gelcoat is still sealed. If fiber is exposed/unsealed, use a light mix of resin to seal it up. I remove any lose pieces and slightly sand the edges of the chipped area. Then I use a high quality epoxy resin (West Marine) with a heavy mix of micro-balloons or silica for maximum bond and durability (you can also add tint to this mix). When I have the right viscocity (like luke-warm peanut butter) I apply the mix to the chipped area using a narrow flat stick and allowing it to spread slightly onto the sanded gelcoat. After the patch hardens up, I use a sanding block with 220, 400, 800 to 1000 grit wet sandpaper to grade the surface to conformity. Finally, I apply a fiberglass rubbing compound to protect the patch.
Good luck!