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Gelcoat Application and Catalyst Data


Materials Coverage
Theoretical-Assuming No Loss
Wet Film ThicknessSq. Ft./Gal.
.001" (1 mil)1600.0
.003" (3 mil)534.0
.005" (5 mil)320.0
.010" (10 mil)160.0
.015" (15 mil)107.0
.018" (18 mil)89.0
.020" (20 mil)80.0
.025" (25 mil)64.0
.030" (30 mil)53.0
.031" (31 mil)51.0
.060" (60 mil)27.0
.062" (62 mil)26.0
Catalyzation

The importance of proper catalyzation when using polyester cannot be emphasized enough. Over catalyzation, as well as under catalyzation, can cause a variety of problems.

Mixing instruction for MEKP catalyst depends on the temperature and preferable dry times. The higher percentage of catalyst the faster it will dry. Air and surface temperature will also affect the drying of the gelcoat. The colder the air temperature, the higher the percentage of catalyst you should use. Do not go below 1/2% or above 2%.

Catalyst Guidline

    Catalyst Percentage
  • 1/2% - (79-85 F)
    Quart: 4-6 cc, Gallon: 23-26 cc, 5 Gallon: 110-130 cc
  • 1% - (72-78 F)
    Quart: 8-12 cc, Gallon: 42-47 cc, 5 Gallon: 220-230 cc
  • 1 1/4% - (66-71 F)
    Quart: 11-14 cc, Gallon: 55-60 cc, 5 Gallon: 275-285 cc
  • 1 1/2% - (61-65 F)
    Quart: 13-16 cc, Gallon: 65-70 cc, 5 Gallon: 335-345 cc
  • 2% - (55-60 F)
    Quart: 17-21 cc, Gallon: 86-94 cc, 5 Gallon: 450-460 cc
Tips
  • 1 mL = 1 cc
  • Gel Coat
    Wet to Cured Correlation
    Approx Mils WetMils Cured
    10 mil7 mil
    12 mil8 mil
    14 mil10 mil
    16 mil11 mil
    18 mil13 mil
    20 mil14mil
    24 mil16 mil
    28 mil19 mil
    32 mil24 mil
    36 mil29 mil


    Information from Cook Composites and Polymers Applications Guide

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