Thanks for the info and link. I had heard others mention the walls needed replaced to prevent future cracking but I was hoping to the exception instead of the rule. I did sand a portion all the way to glass. The glass doesn't show physical cracking along the the lines of the gelcoat, where you could feel it or actually see any separtion, but it did have a crazing type appearance, where you could see a network of fine lines. It looked like staining, like they were airbrushed on, is the best way I can describe the way they looked.

With that in mind I can see how they could come back, and that was a concern for sure, but I was hoping to eliminate it by going with a mostly white (almost everywhere there is glass/gelcoat) and very light tan to for the accent. By storing it under a white cover I was hoping to keep the sun and UV off it except when traveling. My hope was since the plain white gelcoat did not experience any of the cracking, that by laying down white paint it would keep the extreme heat off that area and prevent the same extreme expansion/contraction cycles that caused it where the dark decals existed.

The only reason I could think it might not work out is because if that portion of the panel had already been weakened from the thermal cracking that it might make it easier for the glass/gel to move further than it normally would (like the unaffected areas) with nominal expansion/contraction cycles and it would open back up. I was hoping by knocking a lot of that gelcoat off and building it back up with epoxy it would help stiffen those surfaces to an extent to prevent it.

When I was researching the panel replacement it seemed like it started at $15k (more than I paid for the rig) and could up to $40k depending on the amount of cutting and such and if full paint would be done. So at any of those price points it is kind of out of the question. If I can replace that panel for a reasonable price that has the brunt of the damage I may go ahead and do it. I will look into that.

Whether I replace the panel or I don't at this point I have to repaint it, even if the cracks will start to show through eventually. If they do hopefully I can get away with some spot repairs to keep them at bay over time. The reason being is the ghosting is really bad and on some of the decals the adhesive and ink bled pretty deep down. I've had to sand off quite a bit in some spots and if I just apply new gelcoat to build that back up I'm afraid the repair will stand out. I might be able to get away with sanding down the entire thing a bit to get it to blend together, but I think paint is going to be the best bet.

I have been debating just shooting the lower portion after many of the cracks disappeared with some light sanding. I had considered seeing if that MagicEzy (as mentioned above) or some other type of sealer/repair that worked by capillary action would fill the rest and just live it with it for a while, but I'm still leaning towards paint.

If I can find a base/clear system with a little more flex to it I was hoping that might buy me some extra time before they show through.

This was also why I was debating so much about single stage vs b/c also, or even clear over SS, because if it develops those cracks I wasn't sure if it was going to just show under the clear, or cause the clear to crack. If it would result in the clear cracking then it would almost seem like SS paint might be easier to keep it presentable until I either opt to repair the panels or sell it.

It's like Your Fishing for some one to say it will work BUT I'm sorry it wont.
Its too far gone & The cracks are into glass.
Any thing you put on it will all eventually show through some sooner than others, Paint comes to mind a few weeks max and it will start.

You can try sanding it down with 180 and rolling on Gel coat but I promise it too will start showing the cracks again MAYBE not as fast as paint and maybe not as bad or as fast but it will.
The Permanent repair is to replace the panel.

If it was mine I would sand and Buff it out and put a Vinyl wrap on it and keep it out of sun.