How to Repair Kevlar Kayak Skin

Kevlar is one of the toughest materials from which kayaks are made. A Kevlar skin can withstand a great deal of scratching, hits and thumps, but it may develop scratches or holes over time. The best repair process entails removing material around a hole or even a scratch that leaks, then applying new Kevlar over the opening.

Things You'll Need

  • Scissors
  • Utility knife
  • Sandpaper
  • Vacuum
  • Isopropyl alcohol or acetone
  • Kevlar patch kit with epoxy
  • Cardboard
  • Plastic wrap
  • Brush
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Instructions

    • 1

      Identify the material you are repairing as Kevlar. Different materials require different processes to patch. The boat manufacturer or an outfitter should be able to tell you with what material the kayak is constructed by the brand and model.

    • 2

      Cut away jagged, torn or damaged material from around the hole with a pair of scissors or a utility knife.

    • 3

      Roughen the edges of the opening with sandpaper and sand the hull surface about 2 inches all around the opening. Use caution not to sand too deeply into the Kevlar because it tends to puff up and become difficult to patch. If this happens, use a utility knife to remove the puffed Kevlar.

    • 4

      Vacuum the area near where the patch will be applied to remove loose dirt and fibers. Clean the hull surface around the opening with acetone or isopropyl alcohol.

    • 5

      Cut a piece of Kevlar patch about 2 inches wider than the opening to be repaired. Match the patch thickness to the hull thickness, which usually means three to four layers of Kevlar will be required. Cut the Kevlar patches in successively smaller sizes until the final piece is roughly the size of the opening to be repaired.

    • 6

      Cut a piece of cardboard about 3 inches larger than the opening on all sides. Cover the cardboard with plastic wrap to prevent it from sticking to the patch. The cardboard will act as a holder to keep the Kevlar patch in place while it cures.

    • 7

      Tape the cardboard to the inside of the hull, over the opening to be repaired.

    • 8

      Soak the smallest piece of Kevlar, the one that is the same size as the opening, with epoxy by brushing it on. Epoxy dries quickly, so be careful not to let the Kevlar dry out.

    • 9

      Apply the Kevlar to the opening, against the plastic-coated cardboard, on the outside of the hull.

    • 10

      Repeat soaking each subsequently larger piece of Kevlar in epoxy and applying them, in order of increasing size, one at a time, to the previous Kevlar piece.

    • 11

      Apply a piece of plastic wrap over the final layer of Kevlar to keep it flat and prevent fibers from lifting.

    • 12

      Remove the plastic and cardboard backing once the epoxy has cured.