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Intermittent spray
Possible Causes – Remedies:
Worn gaskets and seals – Replace.
Gelcoat starting to gel – Flush gun immediately with acetone.
Partially blocked jet – Strip gun and clean.
Low pot pressure – Increase pressure to obtain good fan at 50cm distance.
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Difficult to spray
Possible Causes – Remedies:
Delivery lines too small – Increase Diameter of lines.
Gelcoat too cold or too thick – Warm to 15°C minimum or dilute with maximum *2% styrene.
Hard gelcoat in gun – Soak gun in methylene choride or acetone, then blow it dry.
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Poor leveling
Possible Causes – Remedies:
Gelcoat viscosity is too high –
Warm Gelcoat to 15°C minimum. Dilute with maximum *2% styrene.
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Orange Peel
Possible Causes – Remedies:
Atomisation too low – Increase pressure to obtain good fan at 50 cm from mould.
Gun held too close – Hold Gun 50cm from mould.
Gelcoat temperature too low – Warm to 15°C minimum.
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Porosity
Possible Causes – Remedies:
Poor atomisation – Pressure too high gives fine porosity.Or Pressure too low gives coarse porosity.
Gelcoat too cold or too thick – Warm Gelcoat and mould to minimum 15°C. Thin with maximum *2% Styrene.
Excess or wrong catalyst – Maximum 2% catalyst. Check with supplier.
Covering too heavily or too rapidly – Lower gun pressure. Hold gun 50cm from mould. Wet thickness .018 – .023 apply in 3 passes.
Water or solvent – Check the product for contamination.
Gun held too close – Hold gun 0.6-1.0m from mould surface and as perpendicular as possible.
Uneven Catalysation – Service and calibrate equipment.
Wrong or worn tips – Replace tips.
Catalyst fizz – Use correct catalyst.
Use of solvents to thin gelcoat – Do not thin gelcoat.
Pump cavitation – Check equipment for air leaks.
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Sags and Runs
Possible Causes – Remedies:
Applied too thick – Wet thickness 15-20 thou.
Pressure too high – Reduce pressure or move gun 50cm from mould.
Gelcoat too thin – Lower gun pressures, rotate old stock, check with supplier.
Gun too close to mould – Keep gun 50cm from mould.
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Colour separation
Possible Causes – Remedies:
Settling of Colours – Stir before use.
Excessive thinning of Gelcoat – Do not add more than *2% styrene monomer.
Sagging of Gelcoat – Refer to (Sags and Runs).
Overspray – Keep to minimum.
Non-uniform catalysation – Mix thoroughly.
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Resin Tearing
Possible Causes – Remedies:
Gun pressure too high – Lower pressure.
Gelcoat too cold or too thick – Warm gelcoat and mould to 15°C minimum. Dilute with max *2% styrene.
Gelcoat tip worn – Replace tip.
Excessive over spray – Keep to minimum.
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Soft Dull Gelcoat Wrinkling Sticking to Mould
Possible Causes – Remedies:
Insufficient coverage – Apply a total of 18-23 thou. Wet film in 3 passes.
Slow Gel or Cure
– Increase Catalyst to maximum 2%.
Low temperature
– Gelcoat and mould must be min. 15°C.
Trapped Styrene
– Hold Gun at least 50cm away from mould. Adequately ventilate, or tilt mould to expel styrene vapor.
Styrene evaporation
– Do not use over 30°C.
Uneven Gelcoat
– Apply at uniform distance from mould.
Wet P.V.A. Release agent – Dry thoroughly.
Water/Oil in air lines – Flush out and drain traps.
Laminate applied too soon – Do not laminate for at least 2 hours.
Uneven Catalysation – Service and calibrate equipment.
Surge in catalyst delivery – Ditto.
Pre-Release – Refer Pre-Release.
Laminate too slow – Increase catalyst in laminate if temperature low.
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Fibre-Pattern & Print Through
Possible Causes – Remedies:
Insufficient cure
– Correct catalyst level in gelcoat and/or laminate.
Wait longer before pulling. part from mould.
Do not laminate in low temperature.
Check for contamination by water, oil or solvent.
Wait longer before demoulding.
Transferred from mould –
Resurface the mould.
Woven roving / Too close to the gel coat –
Should have 3 layers of 1.5 oz. mat or equivalent chop between gelcoat and woven roving.
Gelcoat too thin
– Use .018 – .023 wet film thickness.
High exotherm of laminate – Cure laminate slower. Laminate in layers.
Use lower exotherm laminating resin.
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Dull part when pulled
Possible Causes – Remedies:
Wax build up on mould
– Polish mould.
Polystyrene build up on mould –
Scrub with stiff brush or stainless steel wool and strong solvent, rebuff and re-polish.
Dust on mould –
Keep mould covered when not in use.
Rough or wet P.V.A. – Apply smoothly and allow to dry.
Releasing part too soon – Allow more time before releasing part from mould, particularly at low temperature.
Raw Catalyst – Start catalyst flow away from mould.
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Pre-Release
Possible Causes – Remedies:
Allowing gelcoat to cure too long –
Gelcoat must be laminated same day.
Use of waxed gelcoat –
Do not use waxed gelcoats on mould.
Excessive or soft wax on mould – Polish mould before use.
Excessive styrene added –
Add maximum *2% styrene.
Over-catalysation at high temp.
– Reduce catalyst to 1% minimum.
Uneven cure due to uneven thickness –
Apply gelcoat to uniform 18-23 thou wet film thickness. Avoid heating or fan blowing before gelation.
Uneven cure due to styrene vapor in low spots –
Ventilate mould properly.
Gelcoat applied too thick – Apply gelcoat at 18-23 thou wet film thickness.
Trapped solvant or water – Check for contamination.
Moving or Bumping mould – Take care until laminate applied.
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Fish Eyes/Pin Holes
Possible Causes – Remedies:
Silicone in wax or polishing cloth – Eliminates silicones in contact with mould.
Contaminating on mould –
Keep mould covered when not in use.
Excessive thinning of gelcoat – Thin maximum *2% styrene.
Thin gelcoat –
Rotate stock, Contact supplier.
Gun pressure too low – Increase pressure to obtain good fan.
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Crazing
Possible Causes – Remedies:
Too much catalyst in hot weather –
Drop catalyst to minimum 1%.
Applied too thick –
18-23 Thou. Wet thickness.
Bad handling when demoulding – Demould carefully.
Applied unevenly – Keep consistent distance from mould when spraying.
Thinning with acetone or other solvent –
Thin only with styrene monomer.
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Blisters, Bubbles
Possible Causes – Remedies:
Air trapped between gelcoat and laminate – Remove with roller.
Over catalysation – Use maximum 2% catalyst.
Catalyst Drops
– Service and calibrate equipment.
Poor catalyst dispersion in gelcoat or laminate –
Mix thoroughly.
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Scratched Gelcoat
Possible Causes – Remedies:
Removal of finished article from mould –
Sand back, buff and polish.
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Fading Or Bleaching
Possible Causes – Remedies:
Poorly cured gelcoat
– Refer to remedies.
“Soft dull Gelcoat”
Under cure
– Allow longer to cure.
Ensure correct catalyst –
Create air flow to remove access styrene from deep areas.
Water exposure (before full cure)
– Do not allow water contact untill gelcoat is cured.
Inappropriate use of shrink wrap
– Use only white pollyethylene film.
Exposure to harsh chemicals – Clean only with mild detergent solution. Do not use solvents strong alkalies or acidic cleaners
Refer to supplier.
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Spider cracks & Stress Cracks
Possible Causes – Remedies:
Impact damage – Take care hammering moulded parts.
Stress due to flexing – Take care demoulding parts.
Allow product to cure.
Gelcoat too thick – Use a wet film gauge.
Mould mark –
Resurface mould.
Laminate too thin –
Increase thickness.
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Yellowing
Possible Causes – Remedies:
Polystyrene / wax build up transferred to part during lay-up – Clean mould regularly.
Poor cure of gelcoat –
Apply gelcoat at correct thickness, catalyst level, and temp.
Avoid contamination by oil, water, or solvent.
Do not add solvents.
Inhibition of cure by styrene vapour.
Thick or uneven gelcoat – Apply at .018 – .023 wet.
Strong Alkaline Cleaners –
Avoid cleaners with Ammonia or high pH levels.
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Flaking Gelcoat
Possible Causes – Remedies:
Faulty adhesion between gelcoat and lay-up –
Avoid use of soft mould waxes, which can penetrate gelcoat and adversely affect adhesion.
Gelcoat left too long before laminate applied.
Pre-Release –
Refer to Pre-Release section
Innappropriate use of shrink wrap
– Use only white polyethylene film.
Contamination –
Ensure no solvent, moisture, catalyst, dust, or overspray is deposited on gelcoat before laminating.
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Pull Marks
Possible Causes – Remedies:
Resin Drainage from laminate –
Avoid resin rich areas.
Uneven laminate cure –
Avoid abrubt changes in laminate thickness
Under cure – Use Correct cat level. Create airflow over mould to remove styrene from deep areas.
Gelcoat too thick – Apply at .023-.025 in 3 passes wet on wet.
Incorrect insertion of cores and stringers – Use compressing material between the item and laminate.