How to Fix a Hole in a Pelican Kayak

Pelican kayaks are made of plastic thermoform. While thermoform is molded differently than polyethylene plastics, you can still repair a hole in a Pelican kayak with plastic welding. Plastic welding is a method of heating the kayak's plastic around the damage and chemically bonding a patch over the break. Plastic welding only requires a few tools and can be managed by someone with no experience manufacturing or repairing kayaks. The advantage is that a plastic weld will often outlast the remainder of the kayak. Hence, plastic welding eliminates the need to replace the kayak with a new one.

Things You'll Need

  • Heat gun
  • Putty knife
  • Carpenter knife
  • Drill
  • 1/16-inch drill bit
  • Leather work gloves
  • Scrap thermoform plastic
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Instructions

    • 1

      Find any cracks in the kayak that branch off the hole in the kayak. At the end of each crack, drill a hole in the thermoform with the 1/16-inch bit. These holes will prevent the cracks from expanding after your plastic weld patch cures.

    • 2

      Measure the diameter of the hole. If there are cracks branching off the hole, consider the cracks part of the hole and measure your diameter accordingly. With your carpenter knife, cut a circle out of your that thermoform that is 1-inch greater than the diameter of your hole.

    • 3

      Place the scrap thermoform over the hole. Turn on the heat gun and allow it to warm up. Pass the heat gun over the patch in long slow passes, never holding it in more than one place for more than a second. If you hold the gun in the same place for too long, you will blister and burn the thermoform.

    • 4

      Once the thermoform becomes pliable, spread the edges of the plastic away from the center of the hole with the putty knife. Allow the thrermoform to cure for an hour.