How to Repair Plastic Kayaks

Polyethylene Kayak

Even with proper care and storage, plastic kayaks can become damaged and require repair. Rough landings against sharp rocks and other unforeseen circumstances can gouge the kayak. Mild scratches can inhibit performance and tracking while more severe cuts can puncture the hull or leave the kayak's integrity in question.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Welding heat gun with nozzle
• Polyethylene welding rod
• Gloves
• Wire cutters
• Sandpaper
• Flat-tip screwdriver

1. Place the kayak in a dry area with adequate ventilation but no wind. Prop the kayak firmly with the repair surface exposed so that pressure can be applied without the kayak moving.

2. Clean the repair surface with a small brush, isopropyl alcohol, and a lint free cloth. Allow to dry.

3. Heat the welding rod tip with the heat gun until the rod visibly starts to bead and melt. Position the welding rod 1/2-inch before the crack and angled toward it.

4. Touch the melted tip of the welding rod to the kayak surface. Aim the heat gun at the welding rod base where it meets the kayak surface. Maintain a distance of 1 to 2 inches depending on the heat setting. Remove the heat if the kayak surface shows signs of excessive melting or warping.

5. Slowly push the welding rod toward the crack. A small bead of plastic will form in front of the welding rod as the kayak surface and welding rod melt together. Continue beyond the crack an additional 1/2-inch and then stop. Remove the heat.

6. Using the wire cutters, cut off the remaining welding rod close to the kayak surface. With a gloved hand, smooth and form the still soft plastic into the crack.

7. Allow the kayak surface to cool and cure before testing. When cool, using a flat-tip screw driver blade, attempt to pry the new weld loose. If the weld comes free, remove it, clean the surface and try again. Once assured of a solid weld, use various increasing grades of sandpaper to smooth any protruding plastic until it is flush with the kayak's surface.

Tips & Warnings

• Before repairing a severely damaged kayak, determine to what extent it is still sea worthy and safe to use. If kayak is beyond repair, contact your local plastics recycler for disposal.

• During winter months, be extra cautious when moving your kayak.

Resources

• Kayak Maintenance and Repair