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That wood looks like it's badly delaminating to me. I would say it's time for new wood. Marine grade or exterior, but not construction grade treated wood, it reacts badly with aluminum and causes corrosion.
I would also suggest sealing in a way that would leave a hard, non permeable surface if...
So, they sent the wrong flake for the Tige, so I've been doing some smaller jobs while we wait for the next batch. I did a quick few spots on a Stingray, a patch job on a waverunner, and just sprayed another waverunner today.
Screwed down through the carpet most likely. The ply is either wrapped in carpet, then screwed to the frame, or screwed down first and carpeted over. Casting decks are usually the former.
Here's an example of a decent patch job that was finished with a brush.
I ground the edges down and gave the whole area a good scuff. Then I taped where I wanted the gel to stop, sanded to the tape edge with 80 grit, and brushed. You have to be quick, and peel the tape before it starts to set up.
You can order gel coat from spectrum that should match the original color, but yours will have years of fade to it. If it was me, I would just look for some white gel with wax and brush it on. It's on the bottom, so who would notice?
If you decide to brush though, I always tape off a square...
A few more things, since I'm off work now. You don't have to worry about getting all of the heavier scratches out, the gel is pretty thick and will fill in a lot. Power sanders will help, but you really want to use a block after you get the bulk sanded down a bit. It also could be sprayed...
There's no need for more glass unless it's low. The process from here would be.
1. Sand with 36 until ~80% smooth.
2. Then switch to 80 grit until smooth and no resin over unscuffed areas.
3. Do a skim coat of bondo, sand with 80, finish with 150. Repeat the skim coats and sanding until...
I can't tell from the pics, too far away. It looks like you just layed a square patch directly over some damage? Any grinding before?
The closest one looks like a hole. Did you fill it in, if so with what?
I doubt it. The risk with power tools is more creating heat and seizing the not to the bolt. I remember doing some fake logs from the log ride at Indiana Beach. For some reason, the bolts for the wheel brackets just kept seizing. I think I even seized one without even using a power tool.
This...