GRP is the backbone of the boating industry due to its versatility and durability




Making a mold


The plug or buck is required first to make a mold. This will be an original art part that is to be copied. These days very accurate patterns can be laser cut or machined to very small tolerances by computer, then surface finished to make a high quality plug. 


The buck or plug, however it is produced must be waxed with several coats of mold release wax and polished in between coats, before the mold may be made. Depending on the desired surface, PVA (Poly Vinyl Acetate) may be sprayed on as an additional mold release agent. However this will reduce the smoothness of the molds finish.


Once the plug has its release agent applied, gelcoat is sprayed or brushed onto the plug. Gelcoat is a pigmented resin without reinforcement. Tooling gelcoat is used for a harder more durable finish.


Molds are usually made from the same fiberglass the part is made from. A mold should be 5 times thicker than the part being made. Such as if a part is made from two layers of 1.5 ounce mat, then the mold should be 10 layers of 1.5 ounce mat. Hence, many layers of fiberglass will be applied, and resin added bonding the fiberglass layers together.


Once the final layers of fiberglass are applied to the mold and allowed to set up, wedges are driven between the plug and the mold to separated the two. When  released you have a negative image of the original part, or female mold.


Making a part


The making of a part is the reverse of making a mold. The mold is waxed, and PVA is applied if desired. The mold will be sprayed with gelcoat in the desired color of the part, then layers of fiberglass are built up to the desired thickness. Once complete, wedges are used to separate the part from the mold.






Pevensey, East Sussex. 



Pevensey Bay Marine specialise in quality GRP (glass) fiber repairs using polyester, vinalester and epoxy resins, to our customers requirements.


We are committed to working closely with our customers to provide them with a service that will meet with all their requirements. The majority of our work is on site repairs. In the marina, or in dry dock. Our expert in sailing boat and power yachts will.


We repair classic racing cars and also produce replacement fibreglass parts. Our skilled craftsmen have 25 years experience in the trade.

We have been repairing boats for over 20 years. As Dateline Marine Services, we looked after many of the Honda Formula 4 stroke off-shore race boats, both 150 and 225 class.

We repair sports boats, jet skis, car bodywork and much more. We also undertake project management for small craft restoration. We offer a mobile/on site repair service for your craft.

We also buy (running or not) and sell outboard motors, small boats and other marine related items.

We offer free advice and a friendly service using only quality approved materials. 




Onsite repairs: LLoyd Stebbings


Tel: 07885 022436

















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