How to Repair Poly Plastic Kayaks

Kayaks can suffer damage from hitting rocks, logs or submerged objects. While minor scratches and dents are expected, and generally need no attention, damage that has compromised the integrity of the hull will need to be repaired by welding over the breach. While the patch will never look as good as new, you can repair poly plastic (polyethylene) kayaks so they are water tight and serviceable. You can make the patch less noticeable if you take the time to match the color of the repair material as closely as possible to the kayak's original color.

Things You'll Need

  • Drill
  • 1/8 inch drill bit
  • Coarse-grit sandpaper
  • Sanding block
  • Putty knife
  • Heat gun
  • Pieces of polyethylene
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Instructions

    • 1

      Work the top and inside edges of the damaged area with the sandpaper, creating a rough surface the patch material can adhere to.

    • 2

      Insert the bit into the drill and make holes at the ends of the damaged area so the patch adheres better along the major stress points.

    • 3

      Turn on the heat gun. Gently pry open the damaged area with the corner of the putty knife, if needed, to reach the inside edges. Heat until the edges of the damaged section, which will be white in color, turn back to the original color of the surrounding plastic.

    • 4

      Heat the outer surfaces areas until they are warm to the touch, then apply heat to the patch material until it begins to soften. As the patch begins to melt, apply it to the damaged area, working it in with the putty knife. Cover the entire area, heating and adding more pieces as needed. Allow the repair to cool completely.

    • 5

      Attach the sandpaper to the sanding block and smooth the area. The plastic will turn white as it is stressed, from being sanded. Gently reheat the area with the heat gun to return it to the original color, if desired.