How to Repair a Drysuit

Water enthusiasts such as boaters, scuba divers, rafters and kayakers invest in a drysuit as an exposure suit that allows them to enjoy prolonged periods of time in cool or cold water. Drysuit shells and gaskets consist of neoprene, rubber, latex or trilaminate material. During routine maintenance, users can protect their investment and save money by examining the suits and repairing small leaks and tears, using supplies available at dive shops and marine supply stores. Users can also stock basic repair supplies in a field kit for on-the-spot repairs (called field repairs), until the suit can be professionally repaired.

Things You'll Need

  • Alcohol wipes
  • Bicycle tire repair kit
  • Duct tape
  • Aquaseal
  • Cotol
  • Plastic plate
  • Brush
  • Drysuit hanger
  • Flashllight
  • Masking tape
  • Neoprene patches or seam tape
  • Latex gloves
  • Optional: timer
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Instructions

  1. Emergency (Field) Repair

    • 1

      Turn the drysuit inside-out and identify the areas that need to be temporarily repaired.

    • 2

      Clean all inside surfaces to be repaired by wiping with alcohol and allowing to dry completely.

    • 3

      Repair a small tear in a latex seal by bonding the two ends together using a bicycle tire repair kit: apply glue to the exposed edges and hold together for approximately 30 seconds. Reinforce the torn area by gluing a small rubber patch on the inside of the seal to cover the hole or tear and allow to dry for at least an hour.

    • 4

      Cover a small tear or hole in a trilaminate suit by covering the inside of the hole with duct tape. Make sure to rub the tape in place over the hole and apply an additional layer of duct tape over this patch and extends at least one inch beyond the affected area. Note: duct tape will not resist water on neoprene drysuits (see section 2 for repair information).

    • 5

      Prepare a mixture of equal parts of Aquaseal and Cotol on a small plate and brush one layer over leaky seams, extending to one inch on each side of the seam. Wait for 10 minutes and apply a second layer of the mixture; allow to cure for at least 20 minutes.

    Leaks

    • 6

      Hang the drysuit in a dark room, such as on the shower rod in the bathroom or a large closet.

    • 7

      Turn on the flashlight and insert the flashlight inside the drysuit.

    • 8

      Hold the flashlight against the fabric on the inside of the drysuit, starting from the feet and slowly moving upwards. It is easier to hold the part of the drysuit being examines with one hand and move the flashlight inside the drysuit with the other hand.

    • 9

      Observe any visible beams of light coming from the inside of the drysuit. If you detect light (indicating a hole), stop moving the flashlight and mark the area to be repaired before continuing.

    • 10

      Continue to examine all areas of the drysuit for leaks and mark accordingly.

    • 11

      Remove the drysuit from the hanger and lay on a flat surface.

    • 12

      Locate the marked areas on the front of the suit and place a corresponding mark of the area on the inside of the suit.

    • 13

      Place a strip of masking tape over the area to be patched (i.e., on the suit exterior).

    • 14

      Turn the suit inside-out and lay on a flat surface.

    • 15

      Prepare a mixture of equal parts Aquaseal and Cotol on a plastic plate.

    • 16

      Apply one layer of Aquaseal over each marked area and extend the coating at least one-half inch beyond the marked hole, wait 10 minutes and apply a second layer. Patch one side at a time (i.e., front side or back side); do not turn the drysuit over.

    • 17

      Allow the sealant patches to dry for at least 30 minutes.

    • 18

      Turn the suit over and repeat steps 11 and 12. If needed, prepare a fresh mixture of Aquaseal and Cotol.

    • 19

      Measure a long tear or large hole and cut the neoprene sealing tape or patch material to cover the area with at least one-half inch of overlap on all sides. Trim the corners to produce rounded edges.

    • 20

      Apply two layers of the Aquaseal-Cotol mixture to the area to be repaired (allowing five to 10 minutes between coats).

    • 21

      Spread one coat of the adhesive mixture to the underside of the seam tape or patch and position the patch over the tear.

    • 22

      Rub the surface of the patch to remove air bubbles and ensure a uniform bond. Make sure you don't shift the position of the patch.

    • 23

      Brush two layers of the adhesive mixture around the edges of the patch, allowing at least five minutes between coats.

    • 24

      Allow the patched area to dry for at least 30 minutes before moving the drysuit or turning the drysuit over.

    • 25

      Hang the drysuit overnight or longer, if possible for the adhesive patches to cure. Turn the suit right-side out and remove the masking tape from the exterior.