How to Fix a Broken Tub and Shower Surround

Cracks

• Cracks and small holes can be repaired with epoxy and fiberglass cloth. Most of the time you will make the repair from the top, but if a leak has already damaged the ceiling below, consider cutting a hole through the subfloor under the damaged area of the tub and repairing from the back. This will reduce the amount of cosmetic work required after the repairs are done. Before you begin your repairs, you’ll need to open up the original break to create enough surface area for the repair to stick to. Apply fiberglass resin and a fast hardening epoxy to the area before placing the first layer of fiberglass cloth. Repeat until the area is filled -- you’ll probably need four or five layers. Wash the area with water, after allowing it to cure overnight, then sand the surface before applying enough additional epoxy to smooth the surface of the repair.

Cosmetics

• Matching the color of your tub and shower surround and reproducing the gloss and texture will give your repairs a more professional look. Gelcoat will give the best looking results but you’ll need to know how to operate spray equipment and deal with various safety issues and bad fumes. A second option involves making your own pigmented epoxy with acrylic paint pigment and color additives. One advantage of using this option is that it can be applied the same day that you finish your repair. You can also use tub and tile epoxy paint to repaint your tub and shower surround so slight color variations won’t be that noticeable.

Refinishing

• Instead of trying to match the color and gloss of your tub and shower surround yourself, you may opt to have a professional refinisher reglaze your tub and shower after you’ve finished your repairs. A professional refinisher uses hydrofluoric acid to dissolve the original glaze and to etch the surface so the new finish will stick properly. He then applies a fast-drying epoxy and several layers of a polyurethane finish coat before polishing the tub. Refinishing a tub cost between $200 and $400 at the time of publication.

DIY

• You can also purchase a refinishing kit from your local hardware store that will allow you to refinish your tub and shower surround yourself instead of hiring a professional. However, these kits contain acetone or alcohol-bonding agents instead of the silane based adhesion promoters used by professional refinishers and they don’t usually last very long. According to professional refinisher, Mike D. Maddocks, owner of Maddocks Refinishing Inc., most DIY kits fail within a year of being used.