Gel Coat issues on my brand new R5!!

[dmnouri]

I want to start off by saying that I previously owned a 2006 Cobalt 232 that I purchased pre-owned and it was one of the best built boats ever. I never had one problem with it. Because of this experience I decided to custom order a brand new R5 as a Christmas gift to my family (wife and 2 kids age 10 & 13). I can’t even tell you how excited we were to get it delivered. After waiting about 4 months it finally came in last month (April) and I took delivery of the boat within 48 hours of it coming in. After I got it home I started finding a ton of gel coat problems which I will list below with pictures:
1) there was an air void near the transom in the gel coat which “popped” soon after getting it home.
2) one of the back cleats were over tightened and has a spider web crack where it is bolted in.
3) there are hair line cracks across the white gelcoat behind the rear chrome air vents.
4) the navy blue hull looked oxidized with some scratches on the side of the hull that was only noticeable in the sun.

I can’t even begin to tell you how this has ruined our whole “New boat” experience. What happened with Cobalts world renowned quality control process!! Of course the dealer is going to fix it all but that puts us without a boat in peak season (when we only have so many weeks/year). Not to mention, I feel like we were handed a lemon. Bentley of boats???? Could you imagine having to have your brand new Bentley go right to the body shop for body and paint work??

[AsLan7]

.
Hello dmnouri. Welcome to the Cobalt chat forum. So glad you found us!

I’m sorry to hear about your gel coat woes. Cobalt quality is still impressive from what we’ve seen on our factory tours.

Have you contacted your local dealer regarding these issues? Cobalt will stand by their product and make things right. See this thread.

Any pics of your prior Cobalt 232 as well as a current overall shot of the current R5?

Again, welcome aboard mate!

.

[dmnouri]

I’ve spoke to them and they are taking it in tomorrow for repairs. Even spoke to a factory rep who said they will be in touch with my dealer - But this many gel coat problems straight out of the wrapper? How did they not see it when I was told they check each boat inch by inch 3 times before it leaves the factory. Anyone else have anything like this happen to them?

[AsLan7]

.
Great to hear they are responding promptly.

Hopefully you’ll get this resolved fairly quickly dm.

....and thanks for the water pic.

.

[Big Block Power]

Yea that's pretty sad. Sorry to hear. I guess this is what I would do. I would use it all summer and drive it to the factory in October or have them pick it up. let them fix it or rebuild it for you. I've heard of them doing a new bottom half or a new top half..

[BeaverLakeR5]

Similar issues with my new R5. Mine has been in twice already for gelcoat repair and I’m still finding other issues (many due to dealer carelessness). I still love the boat but my opinion up to this point of ownership is that my 2005 246 was built quite a bit better.

[Islander208]

Great looking boat. Could we get some pictures of your interior? Don't think anyone here has the Geneva interior. Hopefully they take care of your gel coat issues quickly. Great color combo.

[Ytmsn]

Yeah, I'd do what BB said. Make sure the issues are documented then use it all summer. Take it in this fall and get it fixed. If it happens again next summer, get a new hull or deck. Or both.

At the factory they told us as a boat moves along the line and a worker sees a quality control issue, they circle the problem so it will be addressed before it leaves. I'm not sure what happed with your R5 dmnouri, but I feel confident the factory will make it right.

When we did the factory tour Rick told a story about the 262s when they were in production. Mr St Clair came down to the floor and was talking to one of the engineers about some issue they were trying to work out. The guy said they were working on it and were expecting to get a solution in the next week or two. In the meantime there were a hundred or so boats in production, and St Clair stopped the line and told this guy to get the issue fixed before another boat leaves the factory. They shut down the entire line for a month until whatever it was they were working on was redesigned and corrected. It set a lot of buyers and dealers back quite a bit, as that series was very popular and orders were continuing to flow in, but that's the kind of quality control Cobalt is known for.

Btw, the factory monitors this site, so don't be suprised if you get a call directly from them. Actually I'd be suprised if you didn't.

[dmnouri]

So I just got back from taking the boat to the dealer and when we put the boat on a trailer and started going over the hull inch by inch we found a whole lot more issues in the hulls gel coat. Pin size dots are all over both sides and what appears to be indentions in the hull from where the bulk heads are underneath it. Also found what looks like hair within the gel coat. John From J&M in Morrisville, NC who is apparently the best fiberglass guy in the east coast who specializes in Cobalts said there is so much wrong that it needs to go back to the factory. He said there had to be something wrong with the Mold. In fact he called it a “Friday night special” in that the QC guys clearly didn’t look my boat over (and must have been on a Friday night and they wanted to go home).

Apparently, when a boat needs to go back to the factory it’s gone for months. I’m beside myself. I brought it back home and waiting to hear what Cobalt has to say. At this point I want to return the thing. Stay tuned.

[Big Block Power]

They have all of the molds numbered for this reason. Totally sucks. I couldn't imagine. But if I was in this situation I would again use it for the summer and have the factory pick it up for the winter. Or get them to trade you out of it.

[ajcampen]

What was on your build sheet? Every cobalt is unique but could you find one similar? I would want a loaner for the summer and ask for a next model year cobalt delivered before next summer. Only fair

[tgrace98]

I agree with BBP and AJ. Make them give you a loaner while they make yours right. I know if mine was in the condition yours is in I would not accept it. I would expect them to either replace the boat or it gets sent back to the factory and I would want pictures of all the repairs before it was sent back to me. In the mean time Cobalt and your dealer can work out how to get you on the water until yours is fixed or replaced.

[akorcovelos]

For the price tag, I'd just want them to buy it back and get a new one. They should let you use the boat while they find a dealer with a similar enough build to satisfy you, then have it shipped to your dealer where you can swap it out and not miss any boating.

[BobRae99]

Hi DM,

Sorry to hear about your issues. I have a new R3 on order and wouldn't be pleased to find such defects on my new boat. I agree that the boats should be more carefully inspected before they ship. Having said that, things do sometimes slip through. I firmly believe Cobalt will make things right.

if it was my boat, given the limited boating season (where I live), I think I would log the defects and get an action plan with the dealer and Cobalt and then use the boat for the summer and send it off for repairs in November. You wouldn't be using the boat during that time and it would give the factory or appointed repair centre plenty of time to fix the problems.

The hull and gel coat are warranted against defects and I have no doubt Cobalt will have things corrected. I'd just give them a chance to react to the problem.

BR

[Stuballs]

I had they same/similar issues with the Gelcoat. Dealer sent to fiberglass guy, but frigging ridiculous to be doing Gelcoat work out of the box for what these things cost. My premium stereo is junk, dealer been out 4 times, still sounds pathetic.

Not really impressed with the quality my new R5.