I am thinking of doing the repair on the inside - the outside gel coat is intact so no need to deface that -;)

Given that, does it matter where the kevlar is and if it is on top (e.g. on the inside of the hull, in this case)? Wouldn't any potential fuzzing be covered with the new cloth and epoxy?

I'll see if I can figure out if there is another layer on the inside or if it is kevlar all the way if CD is kind enough to answer. But the hull is paper thin in this area... The boat is the CD Extreme (aka Nomad) by the way if it helps.

I do not have any damaged material sticking up to remove - there are no visible cracks or irregularities on the finish, just the area is somewhat softer and on one side of the deck is barely flattened (1mm or so in from the intended more convex shape as seen from outside) as if something is pushing from outside. So wouldn't sanding be very light and would it cause much fuzzing?

: First I'd check with Current Designs and see if it's Kevlar all the way thru
: and if not on which side it's on. You can not sand Kevlar it turns to fuzz
: that resists sanding. Most of the time there's a layer of glass added one
: one side or the other and that's the side you'll want to patch. You have
: to abrade the surface for the patch to stick btw. Personally if I had a
: choice I'd do the patching on the inside where it wouldn't show.

: You'll need that info first, then come back and ask more

: Bill H.