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Fairing & Surface Repairs Guide

Fairing and surface repair correct imperfections in hulls, decks, and structures before primer and topcoat go on. The workhorse product for nearly all of it is Awlfair LW — proper mixing, sanding, and sequencing of that one product determines whether a repair disappears under the topcoat or telegraphs right through it.

Need help with a project? Call our coatings team: 321-639-3046

Quick Answer: How Do You Fair and Repair Before Awlgrip?

  • Clean and sand the damaged area to expose solid substrate
  • Mix Awlfair LW — D8200 base + D7200 (standard) or D7222 (fast) converter, 1:1 by volume
  • Apply, let cure fully per the product's data sheet, then block-sand smooth
  • Never apply 545 Epoxy Primer directly over Awlfair LW — overcoat with High Build or Ultra Build first
  • On bare metal, apply an anti-corrosive primer (Max Cor CF or Hullgard Extra) before fairing — never fair directly onto unprotected metal

Skipping the High Build overcoat step, or fairing over unprotected metal, are the two most common fairing mistakes we see in the field.

Select Your Repair Scenario

Minor Surface Repairs

Small scratches, sanding marks, or shallow imperfections repaired with trowel-applied Awlfair LW.

View Repair Method →

Fairing Large Areas

Hull or deck surfaces requiring leveling and contour correction over a corrosion-protected substrate.

View Fairing Method →

Sprayable Fairing

Large-surface fairing using a sprayable epoxy compound instead of trowel application.

View Method →

Minor Surface Repairs

Minor imperfections such as sanding scratches, pinholes, or small dents should be repaired before applying the final primer system.

StepDescription
CleanWash surface thoroughly to remove dirt, wax, grease, and contamination
SandSand damaged area using 80–120 grit abrasive to expose solid substrate
FillApply Awlfair LW (D8200 base + D7200/D7222 converter, 1:1 mix) to repair the surface
Sand smoothAfter full cure, sand with 120–220 grit to restore a smooth profile
PrimeOvercoat with High Build or Ultra Build, then 545 Epoxy Primer

Recommended Repair Fillers

  • Awlfair LW (D8200 + D7200 standard / D7222 fast converter) — lightweight, trowelable, the default choice for most repairs
  • Awlfair FL — flexible fairing compound for areas subject to vibration or flex
  • Awlfair Surfacing Filler — finishing filler for the final skim coat over Awlfair LW

Fairing Large Areas

Fairing compounds correct hull distortions, repair structural areas, and create smooth surfaces prior to applying primer systems.

StepDescription
Prepare substrateSand or blast surface to the proper mechanical profile for the substrate
PrimeApply corrosion protection primer such as Hullgard Extra or Max Cor CF — required on bare metal before fairing
Apply fairing compoundApply Awlfair LW (D8200 + D7200/D7222, 1:1 mix) to level the surface
ShapeSand with 36–80 grit to establish surface contour
Final sandSand with 120–180 grit before primer
PrimeOvercoat with High Build or Ultra Build, then apply 545 Epoxy Primer before topcoat

Recommended Fairing Compounds

  • Awlfair LW (D8200 base + D7200 standard / D7222 fast converter, 1:1 mix) — lightweight fairing compound, the standard choice for large-area work
  • Awlfair FL — flexible fairing compound for vibration-prone areas
  • Awlfair Surfacing Filler — finishing filler for the final skim coat

Sprayable Fairing Systems

Sprayable fairing compounds allow rapid fairing of large areas such as hull sides and superstructures.

StepDescription
Prepare surfaceSand or blast substrate to the required profile
PrimeApply corrosion protection primer (Max Cor CF or Hullgard Extra) on bare metal
Apply spray fairingApply Sprayable Fairing Compound (D6001 base + D3011 converter)
Block sandSand fairing with a longboard using 80–120 grit
Final primerApply High Build or Ultra Build epoxy surfacing primer
UndercoatApply 545 Epoxy Primer before topcoat

Typical System

Corrosion primer → Sprayable Fairing Compound (D6001 + D3011) → High Build Primer → 545 Epoxy Primer → Awlgrip Topcoat

Important — Never Fair Bare Metal: Fairing compounds must only be applied over properly prepared and primed surfaces. Applying Awlfair LW (or any fairing compound) directly to bare metal substrates without a corrosion-protection primer underneath is not recommended and will trap corrosion under the repair.
Bottom line: Awlfair LW (D8200 + D7200/D7222, 1:1 by volume) must always be overcoated with High Build or Ultra Build before a finish primer goes on — never apply 545 Epoxy Primer directly over fairing compound.

Recommended Products for Fairing & Repairs

Awlfair LW

D8200 base + D7200 (standard) or D7222 (fast) converter

The primary fairing/repair compound used across every scenario on this page. 1:1 mix by volume. Trowelable, lightweight, sands easily. Must be overcoated with High Build or Ultra Build before 545.

Featured on this guide

Awlfair FL

Flexible fairing compound

Used in place of Awlfair LW on areas subject to vibration or flex, where a rigid filler would crack.

Shop Awlfair FL →

Awlfair Surfacing Filler

Finishing filler

Final skim coat over Awlfair LW or FL for the smoothest possible pre-primer surface.

Shop Surfacing Filler →

Sprayable Fairing Compound

D6001 base + D3011 converter

Spray-only epoxy fairing for rapid large-area work — hull sides and superstructures. Requires spray equipment.

Shop Sprayable Fairing →

High Build Epoxy Primer

D9002 / D8002 + D3002 converter

Required overcoat between Awlfair LW/FL and the 545 finish primer — never skip this layer.

View High Build Guide →

545 Epoxy Primer

D8001 (white) / D1001 (gray) + D3001

The finish primer before topcoat, applied over High Build once fairing is complete. 1:1:½ mix.

View 545 Technical Guide →

Hullgard Extra

D6120 base + D3730 converter

Corrosion-protection primer required under fairing compound on bare metal substrates.

View Hullgard Guide →

Max Cor CF

R4330 base + R3330 converter

Anti-corrosive epoxy alternative under fairing on aluminum and steel. 2:1 mix, spray only.

View Max Cor CF Guide →

Common Fairing & Repair Questions

What is the mix ratio for Awlfair LW?
Short answer: 1:1 by volume — D8200 base with either D7200 (standard) or D7222 (fast) converter.
Long answer: Awlfair LW mixes 1 part D8200 base to 1 part converter. D7200 is the standard-speed converter for typical shop conditions; D7222 is the fast converter, used when you need a quicker cure — for example, in cooler weather or when schedule pressure calls for a faster turnaround between fairing and sanding. Both converters produce the same cured filler once fully hardened; the difference is working time and cure speed, not final hardness or sandability.
Can I apply 545 Epoxy Primer directly over Awlfair LW?
Short answer: No. Awlfair LW must always be overcoated with High Build or Ultra Build first, then 545, before any topcoat.
Long answer: Awlfair LW (D8200 + D7200/D7222) is a filler, not a primer — it's not formulated to provide the surface uniformity or adhesion characteristics that 545 needs to bond to. Skipping the High Build/Ultra Build layer is one of the most common and costly fairing mistakes: the repair may look fine going into primer, but adhesion and gloss problems show up later, often after the topcoat is already on. The correct sequence is always fair → High Build (or Ultra Build) → 545 → topcoat.
Can I apply Awlfair LW directly to bare metal?
Short answer: No. Bare aluminum or steel needs a corrosion-protection primer — Max Cor CF or Hullgard Extra — before any fairing compound goes on.
Long answer: Fairing compound has no corrosion-inhibiting properties. Applying Awlfair LW directly to unprotected metal traps moisture and oxygen against the bare substrate under the repair, which leads to corrosion blistering through the fairing and eventually the topcoat. Always prime bare metal with Max Cor CF or Hullgard Extra first, then fair, then continue with High Build → 545 → topcoat. See the Aluminum and Steel surface preparation guides for the full anti-corrosive sequences.
What's the difference between Awlfair LW and Awlfair FL?
Short answer: Awlfair LW is a rigid, lightweight trowelable filler for most repairs. Awlfair FL is a flexible version used where vibration or flex would crack a rigid filler.
Long answer: Awlfair LW (D8200 + D7200/D7222) is the default choice for the vast majority of fairing and repair work — hull scratches, gouges, hard structural areas. Awlfair FL trades some hardness for flexibility, which matters on areas that flex in service, such as certain deck hardware mounts or thin panel sections, where a rigid filler would eventually crack out. If you're not sure which applies, a rigid area (hull topsides, transom) almost always calls for Awlfair LW.
How long does Awlfair LW need to cure before sanding?
Short answer: Allow full cure per the current Awlfair LW technical data sheet before sanding — sanding a partially cured repair tears rather than cuts, and ruins the profile.
Long answer: Cure time for epoxy fairing compounds varies with temperature, humidity, and which converter (D7200 standard vs. D7222 fast) was used. Sanding before full cure causes the compound to gum up the abrasive and tear rather than cut cleanly, leaving a rough, uneven profile. When in doubt, wait longer rather than shorter — check the current Awlfair LW TDS for the exact cure window at your shop temperature before block-sanding.
Where can I buy Awlfair LW and fairing supplies in Florida?
Short answer: Fiberglass Florida stocks Awlfair LW, Awlfair FL, Awlfair Surfacing Filler, Sprayable Fairing Compound, and the primers used above and below fairing — and ships statewide from Brevard County.
Long answer: We carry every fairing product and primer mentioned in this guide and can spec a complete repair package — fairing compound, corrosion primer, High Build, and 545 — matched to your substrate and repair scope. Browse the Awlgrip catalog, call 321-639-3046, or email orders@fiberglassflorida.com for same-day shipping on in-stock items.
← Previously Painted Surfaces Next: Steel Surface Preparation →

Related Awlgrip Surface Preparation Guides

Need Help With a Fairing or Repair Project?

Our coatings team can spec the right Awlfair converter, overcoat sequence, and primer system for your repair — with same-day shipping on in-stock items from Brevard County, Florida.

Call 321-639-3046 or email orders@fiberglassflorida.com

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