Need Help, Epoxy recommendations - Keel and Tabbing repair

[Carl Wonderful]

This is two different types of repairs and probably best to use two different products. For the keel repair you’re on the right track - clean off the rust and get to bare metal. Some people use a metal treatment like Ospho to convert any last traces of rust to stable metal. I skip that step on my iron keel, but it can help ensure you have a good surface for the epoxy to bond to. After that, and quickly before any new oxidation can form, you coat the keel with a barrier coat epoxy. Barrier coats are epoxy with specific fillers to help build up the right thickness while remaining waterproof. Interlux Interprotect or TotalBoat Total Protect are probably two of the most common for this. If the surface is rough after removing the rust you could apply an epoxy fairing compound like Total Fair to smooth the surface after the first coat of barrier coat. Then build up more coats of barrier coat to ensure the surface is waterproof. The product instructions will say how many coats and the target thickness.

For the tabbing repair you’ll probably be using a more structural epoxy without filler. West Systems and TotalBoat each make good products for this. West Systems has a guide that goes into a lot more detail on this type of repair and that’s a good reference, and TotalBoat has some guides and videos as well. Since you’ll be in colder temperatures you’ll want the fast hardener for whichever product you choose, but even then you’ll need everything to be at least 40 degrees for a proper cure.

Great advice and very specific like I needed so thank you!.

So after I get all rust off, (maybe add rust inhibitor but maybe not necessary..) apply a quick barrier coat (Total protect) right away, then fairing (Total fair) to fill/smooth things out, then more (3...4..?) coats of barrier paint (Total Protect) ...then what? Am I good to go?
Should finalize the keel with some sort of final paint?

 

[jssailem]

In your area I would seek local support as to what is being used that is successful. The folks at Total Boat might have a suggestion. What I use out here in salt water all year might not be the best for you local waters.

It sounds like you have a good plan.

 

[dlochner]

So after I get all rust off, apply a quick barrier coat (Total protect) right away, then fairing (Total fair) to fill/smooth things out, then more (3...4..?) coats of barrier paint (Total Protect) ...then what? Should finalize the keel with some sort of final paint?

Yes, use an antifouling paint that is suitable for freshwater. Check with other boaters in the area for the type of paint that works in your area.

One more step in the keel repair, bring the keel to bright metal and then coat with TotalBoat Rust Primer Metal Treatment. As soon as you remove any rust, it will start rusting again. The Rust Primer stops the rust and forms a paintable surface. It's quick and easy to apply. Let it dry over night and you start apply the barrier coat.

It is absolutely important that you read and follow the directions for the epoxy paint, especially with the ratio of hardener and paint and the induction time. If you don't follow those directions the paint will not cure and you will have a mess to clean up. It is easier to read and print the directions online than to read the fine print on the can. If you alternate primer colors, one coat gray, followed by white, followed by gray, you will be able to see any wear in the paint as the colors will change.