Fiberglass boat application

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Fiberglass Boat application (also “Gel Coat”)



-2 stipple roller sleeves per gallon (Included with purchase of textured gallon) or short nap roller, like a 3/16” mohair or similar for a smooth application.

-40 grit Sandpaper

-Xylene (Xylol) OR Solvide

-Stir stick or electric paint mixer

-Roller Tray

-Cloth or sturdy cotton rag

-Paint Gloves

-Household non-chlorinated detergent, like Spic n Span

-3M Blue tape (Optional)

-Paint Respirator (Optional)


Surface Prep

-Clean the surface thoroughly, with a non-chlorinated household detergent

-Rough up the surface with 40 grit sandpaper

-Wipe down the surface with Solvide or xylene on a cloth and once completely dry, apply the Durabak.


Application Process

-Do not open can until surface is prepped and ready to go. 

-Then open can and stir well.

-Pour a portion into a roller tray and begin application.

-Roll on first coat of textured using Durabak stipple roller sleeve, or a short nap roller for the smooth Durabak.

-Use a paint brush in corners and hard to reach areas. 

-Stir occasionally while working with the product. 

-Keep lid on can while not in use.  



1 gallon of smooth Durabak covers roughly 75-80 square feet in our standard 2 coat application.

1 gallon of textured Durabak covers approximately 60 square feet in our standard 2 coat application.


Good to Know

-Durabak begins to cure with exposure to air, so minimize exposure to air while working with it.

-The consistency of the Durabak should be runny, as it’s self leveling. If it’s thicker, you can add up to 15% xylene to thin it. It should be mixable after adding the xylene and back to a runny form. If it’s pasty and thick, DO NOT APPLY, rather reach out to us for assistance.


-You will have a few hours of work time once the can is opened (3 to 5 hours normally).
-A second coat can be applied after 1-2 hours, once the first coat is touch dry.

-After second coat is applied allow 24 hours before walking on it.  Complete cure is about 5 or 6 days, so no heavy use until then.


Additional Tips

-Temp should ideally be 60 degrees or above for the application, and above 40% humidity.

-Xylene should be applied immediately to clean up any misapplied Durabak.

-If taping off, use 3M Blue tape and remove immediately after second coat is applied at taped off edges, then continue with general application of the second coat.