After being mislead into a different process, I have come up with a new game plan...

The new process will involve mixing the metalflake into the clear gel, instead of laying dry flake on a tack coat.

First, I will spray the entire area with black gelcoat.

Second, I will spray clear gel with the metalflake mixed in.

Third, I will spray several layers of clear in layers with more then 10 minutes, less then 25 minutes between coats. The last couple of layers will include duratech in them for the final finish.

I will be using a HVLP gravity fed gun from harbor freight that will be rinsed between each coat. The boat will be done in sections.

I will take as many pictures as possible and walk through the entire process step by step since this is why I made this site.....There is no solid info/answers out there on how to do stuff like this - just lots of assumptions.

This is no small easy project by any means. I hope my months of research will help someone in the future.

Brad, waht did Kyle think of the name "Golden Shower" for this project?

Brad, have you talked to Todd aka "toddnjuzz" over on Hot Boat about the process? He does gelcoat repair for a living. I'm sure he would give you some pointers.

yes, we have swapped PM's a few times and I have been meaning to give him a call to iron out some details.

Brad, waht did Kyle think of the name "Golden Shower" for this project?

haha....I forgot about that...I will mention it to him when he gets home!

You're lucky, the finest flake guy on the planet is on OC. Sal over at Orange County boat repair .He's got decades of not only glass repair but gel work to. Use to work with him back in the 70s at Hawaiian. None better, period.

I'm going over there tomorrow to get a few things, you can meet me there and I'll introduce you to him if you want. Don't know how much he'll 'give away' as far as advice, but it might be worth the trip for you. It's always fun to see what boats are there and crawl around in them. Hallett, for years, has sent their stuff to him for repairs as well as the bass boat guys. He can match all the big flake too.

Cool guy. Let me know if you want to meet him.

oh yes, sal....

I have spoken with him before...I called at the beginning of all of this to get a quote on this job. He really knew his stuff...even went to great lengths to troubleshoot issues with metal flake gelcoats flaking (something to do with the wax on the metalflake).....his quote was out of my budget so I decided to go the 'weekend warrior' route and try it myself. Why not....ive got more time then money.

I recently called there again asking if he knew of a local metalflake supplyer or to see who he used and he played dumb. 

I would love to meet him and see his shop and pick his brain. Let me know the details and I will try my best to swing by while youre there.

ah, ok...yes, it was sal jr both times who I spoke to......I didnt mean to sound like i was bashing him or his shop in my previous post....just frustrated in this whole deal trying to get information out of people so I get it right the first time. I understand that it took these guys years of their career to master this stuff.

I dont plan on drilling the guy for info, but any tips he might give up would be benificial.