One more thing. I picked up a curved Japanese rasp that I think would have been
great to have when I was doing the portlights. It cuts smoothly and relatively
easily through cured epoxy and other fillers. The curved shape allows you to
cut say just a raised epoxy filler blob without affecting
I found that when I removed the plexi, there were three previous adhesives in
place. Two were softish like silicone and there was definitely Plexus as it was
rock hard. I hand sanded things reasonably level, and did the thickened epoxy
to create a flatter surface. I didn't remove all the Plexus
If the gelcoat damage is just chips, you might consider gelpaste. Spectrum
color makes very nice gelpaste in many custom colors. Gelpaste fixes dings
and chips very well.
Unfortunately, I have no clue which color works best on our boats. They
only have tinted gelpaste for newer boats, like
Dennis,
Fortunately, most of the gel coat damage is under the plexiglas, so it
won't be visible once the VHB and acrylic is in place. Since 95% of the
Plexus is in tact, I am considering filling the chips in the Plexus / gel
coat with epoxy thickened with silica and calling it a day. I
