Hello, I'd like to introduce myself and ask a few questions. I work for a yacht club and do all the structural and cosmetic repairs on fiberglass/gelcoat boats for them. We have 2 custom made 28 foot aluminum launches that are approximately 30 years old and need alot of love. They're structurally sound, couple minor welding areas that I've completed (learning to weld aluminum was a chore) but cosmetically....... I'm at a complete loss as to what to do now. I've prepped and painted the boats the past few years with no problems. Primewashed any bare areas, undercoat, prime, 2 coats paint. Looks nice and shiney beautiful...except a few areas. They would like the boats to be "flat" with no dings and wavering. I have heated and rolled the bad areas so they're relatively flat, and am satisfied with the way that part looks. However. Where the handrails are, from years of use, has slowly bent in. It's not really possible to get under the gunnel to push this back up. It's too tight of an area. Is there anything on top that I can do to flatten this before putting the handrail back on. Someone a few years ago before I got there has used bondo, but of course, it won't bond and just cracks out. If this was a fiberglass boat, no problem. The areas are too large to JB Weld it, each is approximately 4"x4". Any ideas?
