Expert Composite Work & Hull Repairs for Powerboats

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 Composite damage doesn't mean the end of your powerboat. At Powerboat Restored, we specialize in professional composite repairs using both epoxy and polyester resin systems, restoring structural integrity and appearance to hulls, decks, and structural components.

Based in Devizes and serving powerboat owners across Wiltshire, Somerset, Dorset, Hampshire, and Devon, we provide expert composite work with our convenient collection service from any marina or location.

Modern powerboats use composite materials - typically fiberglass reinforced with polyester or epoxy resins. These materials offer excellent strength-to-weight ratios, but they can suffer damage from impacts, stress, osmosis, or age-related degradation. The good news? Composite damage is almost always repairable when addressed by skilled technicians using proper materials and techniques.

Impact Damage 

Collisions with docks, debris, or other vessels can crack or puncture composite hulls. Impact damage ranges from minor gelcoat cracks to severe structural breaches requiring extensive laminate repair.Stress CracksRepeated flexing and stress can cause cracks around hardware mounting points, stringers, or high-load areas. These cracks may seem minor but can propagate if not properly repaired.

Osmosis & Blistering

Water penetration into the laminate causes blistering and delamination, commonly called "boat pox." This requires careful treatment to prevent recurrence.

Delamination

Layers of composite material separating from each other, often caused by manufacturing defects, impact, or water intrusion. Delamination compromises structural strength.

Gelcoat Damage

Surface scratches, gouges, and crazing affect appearance and can allow water penetration if left untreated.

Structural Deterioration

Age, UV exposure, and environmental factors can degrade composite materials, particularly in high-stress areas like transoms and hull-to-deck joints.

We use both epoxy and polyester resin systems, selecting the appropriate material based on your specific repair needs.

Epoxy Resin Systems

Epoxy offers superior performance for structural repairs: Exceptional adhesion to existing laminates and core materials • Higher strength than polyester resins • Better moisture resistance preventing future water intrusion • Lower shrinkage during curing for more accurate repairs • Ideal for structural work including transom reinforcement and major hull repairs . We use epoxy for critical structural repairs where maximum strength and durability are essential.

Polyester Resin Systems

Polyester resins work well for specific applications:• Cost-effective for cosmetic and minor repairs • Faster cure times for quicker project completion • Excellent for gelcoat work matching original construction materials • Good for non-structural repairs like minor surface damage Polyester is our choice for gelcoat repairs and non-structural cosmetic work where it matches the original construction method. 

Our Recommendation

We'll assess your specific damage and recommend the appropriate resin system. For structural integrity, we typically recommend epoxy. For cosmetic gelcoat work, polyester often provides excellent results at lower cost.

Assessment & Diagnosis

We begin with thorough inspection to determine the extent of damage. Surface cracks may hide deeper structural issues, so we use moisture meters, tap testing, and visual inspection to fully understand the repair requirements.

Damage Removal

All damaged material must be completely removed. We grind out cracks, remove delaminated material, and create proper repair edges with appropriate taper ratios for maximum bond strength.

Drying & Preparation

Moisture must be eliminated before repair. We dry the repair area thoroughly and prepare surfaces for optimal resin adhesion.

Structural Repair

For structural damage, we rebuild the laminate using multiple layers of fiberglass cloth and appropriate resin. Each layer is carefully applied, ensuring proper wet-out and consolidation to eliminate voids.

Core Material Replacement

If core materials (foam or balsa) are damaged, we replace them with appropriate marine-grade materials, ensuring proper bonding to surrounding laminates.

Fairing & Finishing

Repairs are faired smooth using epoxy or polyester fairing compounds, then sanded progressively to create surfaces ready for gelcoat or paint.

Gelcoat Application

We match your existing gelcoat colour and apply new gelcoat to repaired areas, blending edges for invisible repairs.

Final Finishing

Gelcoat is wet-sanded and polished to match surrounding areas. The goal is repairs that are invisible and stronger than the original construction.

Transom Repairs & Reinforcement

Transoms suffer tremendous stress from engine mounting and operation. We repair deteriorated transoms and provide reinforcement for engine upgrades or conversions .Our transom work includes: • Complete core replacement if deteriorated • Structural laminate rebuilding • Reinforcement for increased engine loads • Hardware mounting reinforcement

Hull-to-Deck Joint Repairs

These critical joints can fail due to stress or poor original construction. We properly repair and reinforce hull-to-deck joints using appropriate bonding techniques.

Stringer & Structural Grid Repairs

Internal structural components can de-bond or deteriorate. We access, repair, and properly re-bond stringers and structural grids to restore hull integrity.

Keel & Running Surface Repairs

Damage to keels and running surfaces affects performance and can worsen rapidly. We restore these critical areas to original profiles and strength.Deck & Cockpit RepairsSoft decks indicate core deterioration. We repair deck damage, replace deteriorated core materials, and restore structural integrity.

Osmosis requires specialized treatment to prevent recurrence

:Our Osmosis Treatment Process:

1. Blister removal - grinding away affected gelcoat and laminate
2. Thorough drying - allowing complete moisture evaporation (may take weeks)
3. Moisture barrier application - epoxy coatings preventing future water intrusion
4. Gelcoat restoration - new gelcoat application for protection and appearance

Osmosis treatment is time-intensive but essential for long-term hull health.

Specialized Expertise 

Composite repair requires understanding of materials, chemistry, and structural engineering. Our experience ensures repairs that restore both strength and appearance.

Proper Materials

We use only marine-grade resins, fabrics, and core materials from established manufacturers. Your powerboat deserves materials formulated for the marine environment.

Structural Focus

Pretty repairs that lack structural integrity are worthless. We prioritize proper structural repair techniques that restore your powerboat's strength.

Both Epoxy & Polyester Capability

Many repair shops work with only one resin system. We're proficient with both, using the right material for each specific application.

Controlled Workshop Environment

Composite work requires proper temperature and humidity control for optimal curing. Our Devizes workshop provides ideal conditions year-round.

Collection Service

Composite repairs often require extended time for proper drying and curing. Our collection service means your powerboat can undergo proper repair without occupying your marina berth.

Composite repair costs vary significantly based on damage extent, location, and materials required.

Factors Affecting Cost: Damage size and depth • Structural vs cosmetic repair • Accessibility of damaged area • Materials required (epoxy vs polyester) • Gelcoat matching and finishing requirements

Typical Investment Ranges:• Minor gelcoat repairs: £200-£500 • Small structural repairs: £500-£1,500 • Medium hull repairs: £1,500-£4,000 • Major structural work: £4,000-£10,000+ • Osmosis treatment: £3,000-£8,000+ depending on hull size

Request a Quote:

Contact us via WhatsApp with photos of the damage. We'll provide an honest assessment and detailed quote. For complex damage, we may recommend collection for in-person inspection.

Regular Inspections

Annual inspections identify small issues before they become major problems. Look for: • New cracks or crazing • Soft spots in decks or hull • Blistering • Discoloration indicating water intrusionProper StorageSupport your powerboat properly during storage to prevent stress-related damage. Avoid point loads that can cause localized stress cracks.UV ProtectionUV degrades composite materials over time. Regular waxing and covers protect gelcoat and prevent premature aging.

Address Damage Promptly

Small cracks can propagate into major structural issues. Early repair is always more cost-effective than delayed attention.

Quality Hardware Installation

Improperly installed hardware creates stress points. Use backing plates, proper sealants, and appropriate fasteners to prevent stress cracks around hardware.

Don't let composite damage compromise your powerboat's safety or value. Contact us via WhatsApp to discuss your repair needs. We'll provide expert guidance and honest recommendations.

We collect powerboats from any marina across Wiltshire, Somerset, Dorset, Hampshire, and Devon for comprehensive composite repairs in our controlled workshop environment.

Serving powerboat owners across Devizes, the Solent, South Coast, Bristol Channel, and surrounding areas.