First of all this is not RDW this is his nephew. I'm a engineer who rebuilds a variety of things for fun and this is my new victim (second boat). I have never sailed but I hve been restoring this 1970 newport in Kentucky. After a ton of sanding and body work I completed re-gelcoating today. I tried several posted methods but I thought what I ended up with may help someone else.
I mixed 4 oz of med grade silicon sand, from lowes paint store, 8 oz of microspheres and 16 oz of white gel coat. I placed this where I wanted it as a base coat before gelcoat spray. This was so the final gelcoat spray would blend and smooth it. It worked very well. Also i tried a textured roller, smooth foam roller, and a short nap smooth wall roller, all three inch. I found that a slow roll back and fourth motion with the short nap was the most uniform. Also it was better when I dipped it. Temp that day was 72 and humidity was around 45%.
My mixture came down to this: 16 oz gelcoat, 1 oz MEK, 1/8 oz MEKP. Final coat I reduced the MEK to 3/4 and used 1/2 Ounce wax. Brand name of the gel was all Hi-Bond. I only had a few orange peal spots when I rushed or slipped. The gun I used was a $42 Lowes latex spray gun with the thick paint tip which came with it. I got the best results when I cleaned the gun twicw with acetone after each mix. If I could do it again I would have used one gun for half, then used a new for the rest. The gun was great. I also had the ES250 gelgun but it requires one huge air compressor. This requires 40-60 psi at 5-6 cfm I think. Temp was 80 and humidity was 40-45
Hope this helps someone out! I dont plan on sanding much at all. By the way, I tried a roller on a small section
....do not do it unless it is square and very small. That part I will be sanding.