Fiberglass & Gelcoat Repair
Dock rash, stress cracks, soft spots, and holes — repaired with proper laminate schedules and colour-matched gelcoat, so the repair disappears instead of announcing itself from across the harbor.
Most fiberglass repairs fail for one of two reasons: the damaged laminate wasn't fully removed, or the new material was bonded to a surface that was never properly prepared. We grind back to sound glass, bevel a wide scarf, and rebuild the laminate in the same direction the original was laid. It takes longer. It also doesn't come back.
What's included
- Damage assessment, including moisture readings where a soft spot is suspected
- Grinding and feathering back to sound laminate
- Hand-laid biaxial and mat repairs in vinylester or epoxy resin
- Fairing, blocking, and wet sanding to a genuinely flat surface
- Colour-matched gelcoat, sprayed and buffed to blend
- Core replacement in decks and transoms where the core is wet
- Full-hull compounding and polish to finish
What we see most on Duffys
Dock and piling rash
The classic. A windy afternoon, a piling, and a long grey scrape along the topsides. Usually cosmetic, usually a same-week fix, and almost always invisible afterwards once the gelcoat is matched and buffed.
Stress cracks around fittings
Spider cracks radiating from cleats, rails, and canopy post bases mean the load is going into unsupported laminate. We fix the crack and back the fitting properly, so it doesn't simply crack again next season.
Soft decks and wet core
A spongy patch underfoot means water has found its way into the core, usually through an unsealed screw hole. This is the repair people put off, and it's the one that gets meaningfully more expensive with every month of delay.
Colour matching
Duffy gelcoat fades, and it fades unevenly — the sun hits the port side differently than the starboard side in most slips. We match to the aged colour on your boat, not to a factory chip, then feather the spray out so there's no hard edge where old meets new.
Insurance claim? We write estimates in the format adjusters expect and deal with them directly, so you're not playing messenger between the yard and the insurer.
Typical pricing
| Repair | Range |
|---|---|
| Small dock rash or scrape (under 6″) | $180–320 |
| Gouge or crack repair with gelcoat | $340–650 |
| Hole or transom repair | $700–1,600 |
| Soft deck / core replacement | From $1,400 |
| Full hull compound & polish | $16–22 / ft |
Structural and core work is quoted per square foot after inspection. Gelcoat matching is included in every repair price above.
How it works
Four steps, no surprises on the invoice
Assess
Photos, a moisture meter where it matters, and a tap test to find the real edges of the damage — which are usually wider than they look.
Grind & lay up
Damaged laminate comes out, a 12:1 scarf gets beveled, and the structure is rebuilt in glass and resin.
Fair
Filler, long boards, and blocking until the surface is flat under a straight edge — not just smooth to the hand.
Gelcoat & buff
Colour-matched gelcoat sprayed, then cut and polished until the repair blends into the surrounding finish.
Common questions
Fiberglass Repair, answered
How long will it take?
Cosmetic dock rash is usually two to three days. Structural repairs and core work run one to three weeks, most of which is cure and fair time rather than labour.
Can you really match the colour?
On aged white and cream Duffy gelcoat, almost always. Deep metallics and custom colours are harder, and we'll tell you honestly before you commit if a full-panel respray is the better-looking answer.
Will it crack again?
Not if the cause was addressed. A crack around a cleat is a loading problem, not a gelcoat problem — we back the fitting properly as part of the repair.
Do you work in the slip?
Small topside repairs above the waterline, yes. Anything structural, below the waterline, or needing gelcoat spray comes to the yard where we can control dust and temperature.
Ready when you are
Tell us your boat and your harbor, and we'll come back with a free written estimate — usually within one business day.