What happens if a gel coat is applied too thinly?

When gel coat is applied too thinly, one potential outcome is the occurrence of alligatoring. This refers to a specific type of surface defect characterized by a pattern of cracks that resemble the scales of an alligator. Such cracking can compromise the integrity of the gel coat and, in turn, the underlying composite material. Alligatoring can arise from insufficient thickness because a thin layer lacks the necessary structural properties to withstand environmental stressors, such as ultraviolet exposure and mechanical impacts, which can lead to these unsightly cracks.

In contrast, a gel coat that is applied at the recommended thickness is better equipped to provide a protective barrier, as well as aesthetics, since it can maintain its color and gloss over time. This highlights the importance of applying gel coat with the appropriate thickness to ensure durability and a pleasing finish.