Aluminum Boat application – Bare Aluminum

2 stipple roller sleeves per gallon (Included with purchase of textured gallon) or short nap roller, like a 3/16” mohair or similar for a smooth application.
40 grit Sandpaper
Metal self etching primer, like Zinc Chromate, Zinc Phosphate or Metcote.
Stir stick or electric paint mixer
Roller Tray
Cloth or sturdy cotton rag
Paint Gloves
Household non-chlorinated detergent, like Spic n Span
3M Blue tape (Optional)
Paint Respirator (Optional)

Apply Durabak in the first 3rd of the primer's suggested overcoat window - for metcote that is 4 hours after priming, for Zinc Phosphate that is 20 hours after priming.
DO NOT APPLY IMMEDIATELY AFTER PRIMER DRY TIME
Do not scuff or wipe down primer - Durabak goes straight onto it.
Do not open Durabak can until surface is prepped and ready to go.
Then open can and stir well.
Pour a portion into a roller tray and begin application.
Roll on first coat using Durabak stipple roller sleeve.
Use a paint brush in corners and hard to reach areas.
Stir occasionally while working with the product.
Keep lid on can while not in use.

1 gallon of smooth Durabak covers roughly 75-80 square feet in our standard 2 coat application.

1 gallon of textured Durabak covers approximately 60 square feet in our standard 2 coat application.

Durabak begins to cure with exposure to air, so minimize exposure to air while working with it.
The consistency of the Durabak should be runny, as it’s self leveling. If it’s thicker, you can add up to 15% xylene to thin it. It should be mixable after adding the xylene and back to a runny form. If it’s pasty and thick, DO NOT APPLY, rather reach out to us for assistance.
You will have a few hours of work time once the can is opened (3 to 5 hours normally).
A second coat can be applied using a stipple roller sleeve after 1-2 hours, once the first coat is touch dry.
After second coat is applied allow 24 hours before walking on it. Complete cure is about 5 or 6 days, so no heavy use until then.
When applying Durabak it is important to ensure that each coat does not get too thick. If Durabak is applied in a coat that is too heavy it will trap the curing gasses and leave pinholes which will eventually lead to discoloration in the Durabak.
Be sure to apply moderately thin coats of the Durabak and as a guide you should be getting coverage similar to what is laid out above.

Temp should ideally be 60 degrees or above for the application, and above 40% humidity. Durabak is MOISTURE CURED so in High Humiidity the work time and dry time will be substantially shorter.
Xylene should be applied immediately to clean up any misapplied Durabak.
If taping off, use 3M Blue tape and remove immediately after second coat is applied.

Durabak™Application Guide