How to Repair a Hole in RV Fiberglass

Many RV shells are made with fiberglass. If you have an RV with a fiberglass shell and have discovered a small hole or crack in the outer surface, you do not have to take it to a body shop for a repair. You can patch up the shell yourself with some layers of fiberglass and epoxy. The process is not difficult, but it does take a little time to complete.

• 1

  Pop out a panel of wall inside the RV so that you can work on the fiberglass from the inside.

• 2

  Cut out the damaged area so that you have a smooth hole with which to work. Use a hole saw cut it out. Start with a hole that will just incorporate the damaged area. Check the layers of fiber cloth inside the hole to see if they have separated. If they have, cut the hole a little larger until you get to an area where the layers are sealed together.

• 3

  Apply a dewaxing solvent to the area around the hole so that you can remove any debris or grime that is on the surface. Use a rag.

• 4

  Sand the surface around the hole to create a beveled edge around it. The bevel should be thin near the hole and getting less so as it goes out. Make the bevel about 1 foot wide around the hole. Make the bevel on the inside of the RV.

• 5

  Clean the surface with acetone.

• 6

  Smear wax around the sanded area so that the epoxy will not get on surfaces of the RV that are not being worked on.

• 7

  Cover the outside of the RV where the hole is located. Use a piece of Plexiglas and tape it in place.

• 8

  Trim a piece of fiberglass mat 1 inch bigger than the hole itself. Working from inside the RV, spread a gel coat inside the hole. The Plexiglas will keep it in place. Wait 30 minutes to allow the gel coat to start to harden, and then spread the epoxy on top of it. Place the mat over the epoxy and press it in so that there are no bubbles. Spread more epoxy and place a second layer of mat, and then a layer of fiberglass cloth. Each successive layer should be ½-inch larger than the last as you work out from the hole. Once three layers are in place, wait 30 minutes for it to start to harden, then continue with another three layers. Keep doing this until the bevel is filled and the surface is level.

• 9

  Wait for the patch to completely cure, which should be about 1 day. Once cured, remove the piece of Plexiglas on the outside of the RV.