How to Repair a Kevlar Canoe

Although Kevlar, the same material used in bulletproof vests, makes a strong, durable and abrasion resistant canoe, it can't prevent all damage. If you damage a Kevlar canoe, repairing it takes more work than repairing a fiberglass canoe, because you can't sand the Kevlar without it "fuzzing" up. Proper preparation of the damaged area and the surface helps the repair look better and adhere more strongly. When repairing the damage, work in a well-ventilated area in 65 to 75 degree Fahrenheit temperatures.

Things You'll Need

  • Knife
  • 36-, 40- or 60-grit sandpaper
  • 120-grit sandpaper
  • Duct tape
  • Cardboard
  • Plastic
  • Scissors
  • Kevlar patches
  • Marine epoxy
  • Mixing cup
  • Mixing stick
  • Squeegee
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Instructions

    • 1

      Cut around the edge of the damage to remove any pieces of overlapping Kevlar. Removing the overlaps allows to canoe to flex back into its original shape.

    • 2

      Sand around the damage on both sides of the canoe to remove any paint, varnish or gel coat. Sand away enough to create 3 inches of space away from the damage on all sides. Use a 36, 40 or 60 grit sandpaper for speed. The Kevlar will "fuzz up" when sanded. Don't worry about it at this point.

    • 3

      Push the hull back into shape. If the hull wants to remain misshapen, use duct tape, cardboard and creativity to keep it in shape.

    • 4

      Cover one side of the hull with plastic to prevent the repair resin from leaking through.

    • 5

      Mix up enough marine epoxy, according its instructions, to saturate the Kevlar fabric. Use a 1/2 cup of epoxy for a 1/2-foot-square patch.

    • 6

      Cut a patch of Kevlar to cover the damage plus 1 inch. Cut a second patch 1 inch larger than the first and round its edges. Brush epoxy over the damaged area, and place the patches over the damage. The second patch goes over the first.

    • 7

      Brush the epoxy over the Kevlar patch and work the resin into the fabric using a squeegee. When the patch turns from a light yellow to a dark yellow, it's saturated enough. Wait 30 minutes.

    • 8

      Use the squeegee to pull any extra resin out of the patch by applying a light pressure and pulling from the patch's center to its edge. This also pulls out air bubbles and smooths the patch. Smooth the patch, and let it dry overnight.

    • 9

      Remove the plastic and any cardboard.

    • 10

      Repeat on the other side of the hull.

    • 11

      Paint or varnish the canoe's outside to match the original finish.