
Painting a fiberglass boat can be a time-consuming process, but it is a great way to save money and increase the value of your boat. The process of repainting a fiberglass Jon boat involves several steps, including cleaning, sanding, priming, and painting. The boat must be thoroughly cleaned and dried before sanding, and it is important to use the correct type of paint and primer to ensure a successful outcome.
Characteristics and Values Table for Repainting a Fiberglass Jon Boat
| Characteristics | Values |
|---|---|
| Hull Preparation | Requires stringent preparation due to the thinness of each coating |
| Maintenance | Fiberglass boats are not maintenance-free but can look new with care |
| Tools | Shurhold's Dual Action Polisher, high-pressure hose, rags, scrapper |
| Professional Application | Guaranteed result but costly |
| DIY Application | Cheaper but requires extensive work |
| Paint Types | Polyurethanes, Durabak, latex, epoxy base paint |
| Gel Coat | Absorbs a small amount of water to prevent cracking |
| Sanding | Use 80-grit sandpaper, 40-grit sandpaper for fiberglass, 36-grit for epoxy |
| Primer | Compatible primer may be used, especially between paint coats |
| Drying | Allow drying time between coats |
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What You'll Learn

Sanding and cleaning the boat
Before you begin the process of sanding and cleaning your fiberglass jon boat, ensure your workspace is well-ventilated. It is also important to wear protective equipment such as gloves, safety glasses, and a dust mask or respirator to prevent the inhalation of particles or fumes.
Start by thoroughly cleaning the boat with a marine detergent to remove dirt, grease, grime, and other contaminants. This step is crucial as it prepares the fiberglass surface for further work. If your boat has any hardware, such as cleats, railings, or fixtures, it is advisable to remove them before cleaning to ensure a more comprehensive cleaning process.
Once the boat is clean and dry, inspect the surface for any damage, such as scratches, blisters, cracks, or holes. For scratches, lightly sand the affected area using fine-grit sandpaper (usually 600 grit or higher). This will smooth out the scratch and prepare the surface for repainting. If you notice any blisters, drain the fluid, dry the area, and then fill it with a suitable filler. For cracks and holes, clean the areas and fill them with a fiberglass repair kit, ensuring that the repairs maintain the structural integrity of the boat.
If the boat's paint or gel coat is damaged or aged, it may be necessary to remove it. This can be done using a chemical stripper or a mechanical sander. Work in small sections to maintain control during the removal process. After removing the old paint or gel coat, you may need to apply a new gel coat. Once the gel coat has cured, wet sand the surface, starting with fine-grit sandpaper and progressing to even finer grits. Buffing the surface after sanding will ensure a glossy finish.
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Choosing the right paint
Firstly, assess the condition of your boat. If your boat has a gel coat finish, it's important to know that gel coats are not waterproof. They absorb a small amount of water to prevent cracking. If you plan to use a latex paint, ensure the surface is properly prepared, as latex paint can withstand water exposure. On the other hand, if you prefer an epoxy-based paint, you must completely dry and seal the gel coat with the new epoxy paint. This process ensures a durable finish.
The type of paint you choose will also depend on the extent of the repairs needed. If your boat has significant chips, cracks, or holes, you may need to thoroughly sand the surface to create a smooth base for the paint. In such cases, a primer/filler may be necessary to cover up the imperfections and create a uniform surface.
Additionally, consider the level of maintenance you are willing to commit to. Some paints, like Durabak, are specifically designed for fiberglass boats and can save you time and money. Durabak offers a range of products, including a two-part water-based epoxy primer and a top coat, providing a comprehensive solution for your boat painting needs.
The method of application is another factor to consider. Some paints, like the commonly used one-part polyurethanes, can be applied manually using the "rolling and tipping" technique, where one person rolls on the paint while another brushes it out. This method can be labour-intensive but may be suitable for DIY projects.
Lastly, weigh the benefits of professional application versus DIY. While hiring a professional can be costly, it guarantees a high-quality finish. On the other hand, doing it yourself gives you more control over the process and can save you money, but it requires extensive work and time.
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Using a primer
Painting a fiberglass boat is different from painting a house or a car, but it's a job that any relatively handy DIY boat owner can do. The paint you use for a fiberglass boat is very different from the paint you would use for other jobs, and when painting a boat, you may even need to use more than one kind. The best paint for the hull sides and gel coat is different from the paint used for decks, and antifouling paint used on the hull bottom is another variety.
Before applying a primer, you must prepare the surface of your fiberglass boat. Start by removing any hardware and/or fittings, or protecting them with painter's tape, so you don't accidentally damage or paint over stainless steel, plastic, or wood items. Next, dewax all areas that have been exposed to wax. Then, thoroughly sand and/or strip the surfaces to be painted, following the paint manufacturer's instructions. Clean away all the sanding dust and/or stripping chemicals and materials.
If you are painting over a gel-coated area, you will need to power-sand down the gel coat to remove it and access the fiberglass directly. Make sure to consult an expert before doing this—orbital sanders are the best tool for making quick work of the hull. Be consistent and deliberately patient in your approach. You might have to sand down the gel coat around awkward areas by hand. Once the gel coat is removed, wash the exposed fiberglass and ensure it is properly dried before moving on.
Now it's time to apply the primer. Choose a primer and top coat of latex paint, and put two light coats of primer on, with a dry sand in between. Allow the primer to dry fully before proceeding to the next step.
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Applying the paint
Painting your fiberglass jon boat is a time-consuming task but can save you money over hiring a professional. The most crucial part of your painting job is taking the time to prepare. Firstly, clean the boat thoroughly. Use a high-pressure hose, some rags, and maybe even a scraper. It is important to thoroughly rinse and never leave soap on the boat. Next, sand the boat. Use an 80-grit sandpaper to sand the boat's surface and remove all the old paint. If there are areas with epoxy, use a 36-grit sandpaper and be more aggressive. If you are using Durabak boat paint, rough up the fiberglass surface with a 40-grit sandpaper instead.
Now, you are ready to start painting. You can start by using a primer, although it is not necessary with a fiberglass boat. However, if you want to use an epoxy base paint, you will need to completely dry and seal the gel coat with the new epoxy paint. If you are using a primer, make sure it is compatible with the paint you have chosen. After applying one layer of primer, use a 300-grit sandpaper and lightly sand the boat before applying the next coat. Begin painting within 2 hours of completing the primer for the best results.
If you are using Durabak, when using a primer, choose a two-part water-based epoxy. Apply two light coats of primer, with a dry sand in between. Do another dry sand, then a wet sand, let it dry fully, and then apply two coats of the colour topcoat. If you are painting with gel coat, you can use a bucket and broom.
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Drying and sealing
Before beginning the sealing process, ensure that your boat is thoroughly dry. After washing the boat with a dewaxing solvent, use a concentrated water-based cleaning solution like KBS Klean to remove any contaminants such as grease, oil, grime, scum, or residual wax. Dilute the KBS Klean with warm water, apply it liberally to the surface, and scrub thoroughly with a scouring pad. Then, rinse with fresh water and let the boat dry completely.
Once the boat is clean and dry, it's time to start sealing. If you're using polyester or vinylester resin for repairs, you'll need to use laminating resin as it doesn't fully cure when exposed to air. This allows for a chemical bond between the multiple laminates. To seal off the air and allow the final laminate to cure, use either plastic or polyvinyl alcohol (PVA) mould release. For the catalyst, use methyl ethyl ketone peroxide (MEKP), being careful not to confuse it with MEK solvent. Follow the manufacturer's instructions for the hardener ratio, typically around 1-2% by volume. Stir the catalyst thoroughly to avoid undercuring, which can weaken the structure.
If you're sealing exposed fibreglass areas, consider using epoxy paint. Epoxy paint can strengthen the boat and fill any holes or weak spots. Apply a coat of epoxy paint to the exposed fibreglass, allowing it to dry completely before reassembling any parts of the hull.
For a smooth finish, sand the hull after it's dried. Start with low-grit sandpaper and gradually move to higher grits. This process will smooth out any imperfections and prepare the surface for painting. After sanding, apply a layer of protectant to shield the hull from the marine environment.
Finally, when resealing a can of clear coat, use plastic wrap between the lid and the can to prevent permanent sealing. Store the clear coat in a cool, dry place, and always check the touch-cure time, which is typically 2-3 hours, depending on humidity. After the touch cure, allow a full cure of about 7 days before using the boat. Once fully cured, you can wet-sand the finish with fine-grit sandpaper to minimise any imperfections and create a smooth, glossy surface.
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Frequently asked questions
First, clean the boat thoroughly with a high-pressure hose, rags, and a scraper. Next, sand the boat with 80-grit sandpaper to roughen the surface and remove old paint. If you are using Durabak boat paint, use 40-grit sandpaper instead. On areas with epoxy, use 36-grit sandpaper and be more aggressive.
A primer is not necessary when repainting a fiberglass boat, but it can improve the finish. Choose a primer that is compatible with your paint.
You can use either latex paint or epoxy-based paint. If you use latex paint, you will need to scuff the surface with 400-grit sandpaper and apply a primer and top coat. If you use epoxy-based paint, you will need to completely dry and seal the gel coat.
The amount of paint you will need will depend on the size of your boat and the colour you choose. As a general rule, you will need more paint for a larger boat and for darker colours.
You can repaint a fiberglass jon boat yourself, but it will require extensive work and the proper tools. Hiring a professional will result in a guaranteed finish but will cost more.










































