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post #3 of Old 06-23-2013
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Re: Using brush instead of spray for gel

Yes, you can use a brush.

The challenge on vertical surfaces is keeping the gel from running/sagging. If you use a piece of acetate over the top of the repair, you can keep it in check. Tape all the way across the bottom first, apply the gel, then roll the acetate up over the repair. Use a plastic squeegee or body filler spreader to work it relatively flat. Tape the top, then tape the sides. The good thing about the acetate is that it will leave you with a pretty fair surface. The bad thing is that with the molded planking, you're gonna have to reestablish all those grooves.

I've tried to get a Preval sprayer to work with gel, but have had little success. The problem is that the you need to thin the gelcoat considerably to get it to spray well. A couple of suggestions if you decide to go this route:
- Pull the strainer off of the pick-up tube on the sprayer.
- Thin the gel with Styrene only. Acetone will work, but it flashes really quickly.
- Adjust your mix before you add any catalyst. Spray onto a piece of glass, and add styrene until you get a coat that covers smoothly but doesn't sag/run.
- Add the amount of catalyst needed for the volume of the total gel & added styrene in the bottle. If you only add enough catalyst for the gel you started with, then the gel won't dry fast enough.

Good luck which ever method you choose.

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