I have a little experience with gelcoat. Yes, it will always orange peel. It also can be put on too thin and too thick, with detrimental side effects for each. Too thick and it doesn't flex and will star on impact, and too thin and it will crack into pieces and come loose. Around .025 was optimum for what we used at Correct Craft. Ask the supplier if he has any info on it, and do your best. Block sanding and building it up slow was the way our repair dept did bad areas. Prep and cleanliness is very important. That's a slick little boat, you'll have fun during and after the re-fit. Good luck and keep us posted.
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