Crack Repair

Yep, let the comments begin on the title . . . Here is a site with some helpful info and products should you need to repair your plastic boat -


Step-by-step Instructions
Step 1

This is a typical crack that you might find on the bottom of a kayak. The first thing you need to do in any plastic repair is to clean the plastic. Use soap and water to remove any water soluble contaminants. Use a plastic cleaner like our Part Number 1000 - Super Clean Plastic Cleaner to remove any sovlent soluble contaminants. Super Clean Plastic Cleaner will remove contaminants that won't come off easily with soap and water. Contaminants like grease, tar, sticker residue, etc. Realign the plastic if is has overlapped itself.
Step 1



Step 2

To maximize the strength of the repair, it helps to embed some wire mesh into the plastic. It is similar to putting rebar in concrete. Cut some of the included wire mesh to span the crack about an inch on side. On this particular repair, we had to fold the mesh because the crack was on a corner.



Step 3

Using the KC Welder, melt the wire mesh into the plastic. This is similar to putting rebar in concrete. It makes the repair a lot stronger. Sometimes, the mesh wants to "pop out" of the plastic before the plastic cools. If that happens, use a screwdriver or another tool to hold the mesh into the plastic until the plastic re-solidifies.
Bury the wire mesh


Step 4

Here is what it will look like once the mesh has been melted into the plastic.


Step 5

Apply the filler rod by pre-melting one side of the rod.



Step 6

Flip the filler rod over so that the melted side is toward the plastic that you are working on.


Step 7

Cut the tip of the rod off by melting through it with the edge of the welder tip.


Step 8

Spread the melted rod while pushing it through the mesh. You may need to apply an extra layer of rod after pushing it through the mesh. Get the plastic hot enough so that the new melted plastic melts together with the existing plastic.



Step 9

Continue applying plastic until the crack is repaired completely.



The repair is complete.


The web page: http://www.urethanesupply.com/kcwelder.php
The Welder: http://www.urethanesupply.com/Kayak-and-Canoe-Welders-1/

Nicely done!

That boat should have many more years on the water.

nicely done. in my experience I've found welders with a feed hole like the one sold by Hobie are better than the ones like you used for feeding material in a crack. However the hot air welders are way better than both. I think you can get them at Harbor Freight too.

that looks Jus'Gwargees!    good job!

Hey that's the same way the Doctors repaired my hernia! 

Just kidding...that's great work and even better pics. Thanks!

  Bomb proof !      Great idea using mesh.   

Nicely done. Anyone every dabble in Royalex repair?

Yep, let the comments begin on the title . . . Here is a site with some helpful info and products should you need to repair your plastic boat -


Step-by-step Instructions
Step 1

This is a typical crack that you might find on the bottom of a kayak. The first thing you need to do in any plastic repair is to clean the plastic. Use soap and water to remove any water soluble contaminants. Use a plastic cleaner like our Part Number 1000 - Super Clean Plastic Cleaner to remove any sovlent soluble contaminants. Super Clean Plastic Cleaner will remove contaminants that won't come off easily with soap and water. Contaminants like grease, tar, sticker residue, etc. Realign the plastic if is has overlapped itself.
Step 1



Step 2

To maximize the strength of the repair, it helps to embed some wire mesh into the plastic. It is similar to putting rebar in concrete. Cut some of the included wire mesh to span the crack about an inch on side. On this particular repair, we had to fold the mesh because the crack was on a corner.



Step 3

Using the KC Welder, melt the wire mesh into the plastic. This is similar to putting rebar in concrete. It makes the repair a lot stronger. Sometimes, the mesh wants to "pop out" of the plastic before the plastic cools. If that happens, use a screwdriver or another tool to hold the mesh into the plastic until the plastic re-solidifies.
Bury the wire mesh


Step 4

Here is what it will look like once the mesh has been melted into the plastic.


Step 5

Apply the filler rod by pre-melting one side of the rod.



Step 6

Flip the filler rod over so that the melted side is toward the plastic that you are working on.


Step 7

Cut the tip of the rod off by melting through it with the edge of the welder tip.


Step 8

Spread the melted rod while pushing it through the mesh. You may need to apply an extra layer of rod after pushing it through the mesh. Get the plastic hot enough so that the new melted plastic melts together with the existing plastic.



Step 9

Continue applying plastic until the crack is repaired completely.



The repair is complete.


The web page: http://www.urethanesupply.com/kcwelder.php
The Welder: http://www.urethanesupply.com/Kayak-and-Canoe-Welders-1/

I'm going to come see you when I have crack issues.
You are like the kayak proctologist 
Nice work buddy!

Great tutorial. Could come in handy some day. We have plastic items at work and the need to repair them has come up before. I am going to show them this and some other links I looked up on different welders and welding rods. While I was looking I found this PDF that has helpful info and tips on doing plastic welding. It is related to a high end professional system but I think a lot of the info applies here as well.

http://www.bestmaterials.com/PDF_Files/BAK-Plastic-Welding2.pdf

Where can you get the filler rod?

Kayak shops have filler rod, i use hdpe shampoo bottles in a similar color...