What may result from a gel coat layer that is too thick?

A gel coat layer that is too thick can lead to cracking, particularly in radial or divergent configurations. This is because excessive thickness can create tension within the material as it cures and sets. When the gel coat is applied too thickly, it is subject to shrinkage and stresses that can result in cracks forming. These cracks can manifest in various patterns, often aligning with the geometries of the underlying structure, which can further compromise the integrity and aesthetics of the composite part.

While other potential outcomes exist, such as extra weight being added to the part due to the thicker gel coat, the most significant and damaging effect is the occurrence of cracking. This can undermine the purpose of the gel coat, which is to provide a smooth finish and protective barrier against environmental factors, and can ultimately lead to more costly repairs or necessitate replacement of the affected composite parts.