OK just got my next order from USComposites for my bilge. I got 2 gals white gel 1 gal clear duratec and styrene. I plan to give everything one coat of gel/ styrene and second coat gel/duratec. Now I'm hoping to be able to roller this with a small roller, I'm not looking for show quality but I want a good solid coating. How should I prep everything, Its all new vinylester? Also how do I mix the hardener for the gel/duratec (1gal gel 1 gal duratec)? Does this all sound right? Thanks in advance
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do you have wax in the resin? it wiil need to be wiped down with acitone and then sanded first .. if youe using a bruse or roller you wonr need the styrene and if you mix the gel with the duratec that alone will thin out the gelcoat to be sprayed..you mix the activated duratec with the activated gelcoat 1 to 1 mixture then i usually use a chitty old dordless drill with a dull wood bit with the point ground off. try to get rid of all the dust as well..also apply one coat and let it kick off then apply the second..i like to spray it on ..goes faster..

Brushing on gelcoat is a tough job. You will have about 10 minutes of working time after you mix your gelcoat.

Do some research on "dump guns" for shooting gelcoat. I used one for the straight gelcoat and then used a, throw away, hvlp gun from hazard freight to shoot the gel/duratec mix.

The hardest part of the process is the lack of working time with the mixed product so, you have to have everything planned out to a t and you have to move quickly.

Hope this helps,
Rob.

Thanks guys, I think I'll experiment with spraying the gel/ duratec. How many coats of gel/ duratec should I lay down after my initial coat? And what should I fair out the new fiberglass with so it looks a little smoother?

Based on a phone conversation with the Duratec manufacturer, I mix the D and gel 1 to 1 then catalyze as usual based on weight. Home Depot sells a solvent resistant white foam weiner roller that will give you a better finish than poor spraying with very little orange peel. The roller will begin to expand after about ten minutes so just switch to a new roller if necessary. I did over 50 sq. ft. on my Cigarette this way, and it turned out great. Be careful though as the Duretec cuts the opacity of the gel by 50%. I would suggest a couple of coats of gel with MEK peroxide, no wax, then do the final coat with Duretec for a hard finish.

OK guys thanks for the info and the encouragement to spray the gel. I rollered the first coat and wasn't impressed at all so I went down to the garage drilled my spray gun out with a 5/64 and sprayed 2 coats of straight gel and then gel/duratec coat. I must say spraying is the only way to apply gel. Here's what I ended up with.
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No wax with duratec it will kick it no problem . I would do 2 coats of gel with no styrene and then 5050 and it will look like glass. We do it all the time.

Same here, I like that recipe. I usually whale down a couple heavy waxed coats to get my color coverage then sand that down to fair the surface a bit. Then come back with the a full 50/50 Duratec/gel mix.