The plastic kayaks are pretty durable but someday if you
should develop a leak it can be repaired with a small propane torch
or other heat source and some polyethylene (plastic) material. "See below for repair instructions"
The Polyethylene Weld Kit (on left) contains plenty of repair polyethylene cut into narrow
strips, a couple larger pieces for larger repairs, sandpaper and
directions. Specify kayak color or you'll get a mix or colors.
The Rec Repair Kit (lower left)is a great safety item to take on
kayaking trips. It comes in 2 sizes, small for carrying on overnight
trips and the large kit that can last for a long time and do many
repairs. It's meant for use away from civilization but will also work
anywhere at anytime. The polyethelene sealing material comes in a
waterproof pouch with it's own heat source. Just activate the heat
pouch, apply the material to your kayak and when it cools, you're ready
The Patch and Go is a repair paste that comes in a tube. It is not
meant for structural repairs but it will seal smaller leaking areas
that don't affect the structural integrity of the kayak. The Patch and
go is easy to use. Squeeze enough on to cover the leaking spot. Apply
some heat and it adheres to the plastic. Don't depend on the Patch and
Go anywhere the kayak is likely to get flexed because flexing will
likely break the seal. It doesn't really provide any strength .
Hint: At some point kayaks spending too much time in the direct
sun will become UV'd enough that the plastic will be brittle and
start cracking. You may repair it but when it becomes brittle enough,
it will continue to crack over and over again. The solution is to get a new
kayak and keep it stored out of the direct sun as much as possible.
Bring us a leaking kayak and we'll pressure test it, find the leak
and repair it (if it's repairable) for a $25 minimum charge. However,
we won't repair UV'd brittle kayaks that we feel will soon be cracking
these weld kits all over the U.S. For the Poly Weld Kit, the combo kit
or the Rec Repair Kit it's usually just $4.95 shipping, USPS priority
mail, anywhere in the US.
To order your repair kit send us an Email
or call 808 880-1400 We can accept M/C or Visa and shipping usually takes just 3-5 days
Repairing Plastic (Polyethylene) kayaks with a propane torch
First you need to acquire some polyethylene plastic or order our
polyehtylene Weld Kit. A mini propane torch works best since it's
easier to control the heat but a standard propane torch (plumbing repair type) can also work
if you keep the flame low.
For smaller repairs I like to cut the plastic weld material into narrow
strips so it's easy to heat and apply like a welding
For doing longer cracks or larger holes, use one piece of material and
cut it sized to cover the entire damaged area.
Rough up the area with sand paper 80-120 grit prior to welding as well
as in between welds if you've allowed it to cool.
Work in a shaded area. Out in the sun it's very hard to see how much flame is being applied.
If you've got extra repair material it usually pays dividends to do little
test repair, melting one piece of repair plastic to another just so you
know how fast it melts and how they bond together
Heat the repair plastic more than the kayak itself. You would like the
repair plastic to fully melt but not fully melt the kayak for obvious
reasons. I usually heat the repair plastic first (especially with the
narrow welding rod plastic) and get it melting then apply it to the
kayak heating both together making sure not to overheat/melt the kayak
itself. After allowing the repair to cool, sand or surform excess plastic
Most people are more interested in making the repair waterproof than
making it look perfect. If you're repairing a crack and the finished
look matters greatly to you, use a dremel type tool to cut a vee along the
crack. Fill in the vee with welding rod plastic strips. Sand or
sureform any excess for a smooth finish......