Epoxy didn't dry... put a "patch" on

Anthony A

Well-known member
Not quite sure I did the right thing.

I put the final coat of epoxy on the bottom of my Kara two weeks ago (after bolting in the runners and epoxying those) and for some reason, 4 dime-sized spots simply refused to dry/cure. I think that the last batch of epoxy I mixed was perhaps not as well mixed with hardener on the bottom of the mixing bowl since that was the last section I did. Also, even after two weeks, the boat "felt" stickier than previous epoxy coats - could this be due to humidity?

In any case, I did not have much choice as my friend was moving and he needed his garage to store things for this weekend! So we went ahead and sanded the boat. It became apparent that the epoxy hadn't completely cured, there were little splotches of epoxy on our sanders. Not too many that would make the sanding difficult, and there was no apparent exposure of deeper layers. When we got to the trouble area, the 4 dime-sized spots were made apparent. I gently scraped out the gooey material as best as I could with a spatula - the fiberglass was still intact underneath, and it didn't feel like the epoxy coats right next to the FG were comprimised, although it was difficult to tell since it was still semi-wet.

I decided to "patch up" the whole section with my remaining epoxy by mixing in a good bit of wood flour to make it pasty like peanut butter (it worked well on the transom and on the runners). I checked it at lunch time today as I went over to plug in my de-humidifier (too little too late, I know), and it seems to be drying quite nicely!

My question is could this patch be a problem down the road? The only thing I could think of is if I scrape that section of the boat very badly on some rocks , it could expose the inner layers of the boat? Is it weaker the way I did it? Should I have been more aggressive in removing that layer of epoxy from the surrounding area and re-applied regular epoxy?

As always, your comments and ideas are always welcome!

Anthony
 
Anthony,

It may be fine, but it may not. All sticky/gooey material must be removed to get a good bond and have a top quality fix. In an ideal world you woudl sand to unsticky material or remove all the sticky material with a solvent like acetone. Either way the material above the gooey residue will not bond to the residue if there is any left, but it will bond to the edges that are good. Either way, it sounds cosmetic since ti is above (after) the glass coat. I'd leave it and fix ti if it fails by sanding down to the glass and recoating if it does fail. It is easy to get sloppy with your mixing towards the end of a project, I've done that and it sounds like what happened here..

Just to set things straight, and you may know this and are just imprecise with your termonology, but epoxy doesn't dry, it cures. Humidity doesn't have a whole lot to do with curing rate, but it can affect the degree fo blush you see.
 
If it's any consolation, the same thing happened to me right around the same stage of boat construction. I'm fairly certain it resulted from mixing too small a batch of epoxy (I was working with the remnants at the bottoms of the containers, and I strongly suspect that I got the ratio wrong).

I think I broke down, purchased an additional bottle of both epoxy and hardener, sanded and scraped the poorly cured spots off, and put down a new coat of epoxy (this time being careful to get the ratios correct). I've taken the boat out about 20 times now, and it seems to be fine.
 
Thanks for the observations. I tried to dig out the gooey stuff as best I could. They were really small spots. The spatula started to dig under the layer and was breaking off tiny sections of already cured material (at least I think it was cured) - kinda like thin slices of glaze on one of those fancy pastries :)

I guess I'll have to wait and see if the patch will bond, then i'll know whether or not I should have been more aggressive with the removal of uncured epoxy from that area.

What do you mean by blush? I've never heard the term in this context.

Anthony
 
Thanks for the observations. I tried to dig out the gooey stuff as best I could. They were really small spots. The spatula started to dig under the layer and was breaking off tiny sections of already cured material (at least I think it was cured) - kinda like thin slices of glaze on one of those fancy pastries :)

I guess I'll have to wait and see if the patch will bond, then i'll know whether or not I should have been more aggressive with the removal of uncured epoxy from that area.

What do you mean by blush? I've never heard the term in this context.

Anthony


A,

Blush has nothing to do with this situation. The only reason I mentioned blush was because I mentioned humidity, which can affect blush formation. Blush is not what you saw from your description - it is a waxyish layer that forms on the top of some epoxy under some conditions. Blush must be removed from cured epoxy before another layer can be put down or the top layer won't bond well to the layer that the blush formed on.

Either way just hunt the boat if the problem is in a layer above the glass. The layers above the glass don't do a whole lot and are mostly cosmetic. If you have a problem and your patches fall off just sand the areas out, get some new epoxy and recoat a couple times.
 
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