• Low-viscosity, high-strength, solvent-free epoxy system
• Ideal for laminating, coating, bonding, and barrier coating
• Provides superior moisture resistance and strength
• Mix with a wide range of fillers for bonding and fairing applications
• Compatible with wood, fiberglass, and properly prepared metals

TotalBoat Traditional 5:1 Epoxy System is a high-performance, low-viscosity epoxy that cures to a rigid, moisture-resistant solid with superior adhesive strength. It’s perfect for coating, laminating, bonding, and barrier coating applications on wood, fiberglass, and composite structures. Available with your choice of TotalBoat 5:1 Epoxy Fast Hardener or TotalBoat 5:1 Epoxy Slow Hardener to accommodate working conditions and cure times.

Product Information

Cleaner / Surface Preparation

• Acetone
• Denatured alcohol

Cleanup

Use denatured alcohol or acetone before the epoxy cures. Once cured, epoxy must be removed mechanically.

Thinner / Reducer

Do not thin epoxy. Thinning compromises strength and moisture resistance.

Mold Release Agents

Use paste wax or approved aerosol mold release agents for composite molds or plugs.

Primers

• Not required for most substrates.
• TotalBoat Aluminum Boat Etch Wash is recommended for aluminum.
• TotalBoat Rust Primer is recommended for steel or iron.

Applications

Laminating, coating, barrier coating, bonding, fairing, filleting, and small gap filling.

Acceptable Substrates

Wood, fiberglass, epoxy, and properly prepared metals such as aluminum or steel.

Safety

Always wear gloves, safety glasses, and proper protective clothing when handling epoxy. Work in a well-ventilated area and avoid skin contact. Review the Safety Data Sheet for detailed handling information.

Exothermic Reaction Warning: Mixing large quantities of resin and hardener can generate extreme heat and cause the mixture to cure rapidly. Always mix small batches to control working time and temperature.

Surface Preparation

Surfaces must be clean, dry, and free of oil, grease, wax, and other contaminants before applying epoxy. Always use clean cotton rags for solvent cleaning.

Wood

• Wipe oily woods, such as teak or mahogany, with denatured alcohol or acetone before sanding.
• Sand with 80-grit paper and remove sanding residue before applying epoxy.

Fiberglass

• Remove amine blush or wax contamination with warm water and mild soap.
• Sand with 80–100 grit paper and clean thoroughly before applying epoxy.

Metals

• Steel / Iron: Sand or grind to bright metal, wipe with solvent, and prime with TotalBoat Rust Primer if desired.
• Aluminum: Abrade and apply TotalBoat Aluminum Boat Etch Wash before applying epoxy.
• Lead: Sand bright, solvent wipe, and apply epoxy immediately to prevent oxidation.

Mixing & Dispensing

• Mix ratio: 5 parts resin to 1 part hardener by volume.
• Use calibrated TotalBoat 5:1 Epoxy Pumps for consistent mixing (1 pump resin : 1 pump hardener).
• Stir thoroughly for at least 2 minutes, scraping sides and bottom of mixing container.
• Mix only the amount that can be applied within the working time.
• Do not vary the mix ratio or thin the epoxy.

Applications

Laminating

Apply resin evenly with a roller or brush, ensuring complete saturation of fiberglass fabric without puddling. For best strength and clarity, use multiple thin coats.

Bonding

Use thickened epoxy for gluing or structural joints. Add fillers as needed for gap filling or additional strength. Apply moderate clamping pressure—avoid over-clamping, which can starve the joint.

Filleting

Mix epoxy with fillers to achieve peanut butter consistency. Apply along joints and shape using a rounded tool for a smooth, concave finish.

Fairing

Mix epoxy with fairing fillers such as microballoons or lightweight fairing compound for easy sanding and shaping.

Barrier Coating

Apply multiple coats, typically 3–5, to build a total dry film thickness of 10–15 mils for excellent moisture protection and durability.

Adding Fillers & Thickeners

• Silica: Increases viscosity and improves adhesive strength.
• Microballoons: Creates lightweight, sandable fairing compound.
• Wood flour: Ideal for wood-tone bonding and fillets.
• Milled fibers: Adds structural strength to joints.

Tinting & Pigmenting

• Compatible with TotalBoat Pigment Dispersions, TotalBoat TotalTint Mixol Universal Pigments Kit, mica powders, and alcohol inks.
• Mix resin and hardener thoroughly before adding colorants.
• Test small samples to confirm desired color and compatibility.

Curing & Clamping

• Cure time depends on temperature, hardener speed, and applied thickness.
• Do not over-clamp when bonding — maintain a thin adhesive film.
• Allow a minimum of 24 hours cure before sanding or recoating, depending on temperature.

Storage & Crystallization

• Store sealed containers in a dry location between 60–90°F.
• If crystallization occurs, warm sealed container in 130–150°F water bath for 30–90 minutes to restore clarity.
• Proper storage extends shelf life to one year or more.

Overcoating & Topcoats

• Wash cured epoxy with warm, soapy water to remove amine blush before sanding.
• Sand with 80–220 grit prior to recoating or applying paint or varnish.
• For gelcoat applications, use an epoxy-compatible primer such as TotalBoat TotalProtect or 2-Part Epoxy Primer.

Application & Physical Data