470 Dinghy Rebuild

[Darren.R]

I am rebuilding/refinishing an older 470 olympic class dinghy. I'm looking ar refinishing the gel coat surfaces, and want to know what to use to keep strength high and weight low. Also the side tube sections have "soft" spots from years of sitting/hiking on them. What can be done or applied to the tops to bringbacg the strength and prevent future denting/softening. To remain class legal I think I have to use standard "glass" material - no kevlar or carbon fiber.
All suggestions are welcome.

[Ric@Noahs]

Two part Polyurethane paint such, as Sikkens Polyester Yachtpaint would be the best way to restore the finish and keep it light. As for the soft spots, there is probably a foam or balsa core between two glass skins. The core has crushed and needs to be replaced. The best way to do this without adding weight is to remove one of the fiberglass skins, replace the crushed core, replace the glass, then paint. The easier, but not as good a solution is drill some ?? holes and inject Epoxy Resin. If it is solid fiberglass you will just have to add more glass to stiffen it
Have fun.

[Darren.R]

It is only glass construction, no core. What do I need to do to remove the gel-coat, and how far do I go down (till weav shows?) After the gel-coat is removed, what prep do I need to do to procede with glass etc? What type of cloth will yield the best strength to weight ratio. What would be a good filler and primer to use prior to paint?
Is there a source for pre made glass channel that can be applied for support on the undersides and floor? (newer boats have two extra channels on the floor to strengthen)

Thanks

[Ric@Noahs]

I think your best bet would be to either take it to a pro or invest in a book on fiberglass repair. Afraid there is too much involved to cover it here. It would be easier for you to use Epoxy Resin, if you are not used to working with fiberglass. The ribs are made in place. You can use a cardboard tube or a piece of wood to get the shape, and fiberglass over it. Can send you a application brochure on Sikkens Yachtpaints if you wish.