How to Repair Kayak Holes

As small boats, kayaks get bumped around and eventually will need repair. If a small hole occurs during an outing, simply patch with duct tape and enjoy the day. Upon returning home, a small hole in a kayak is relatively easily remedied with a few hours of tender love and care. The material out of which the kayak is constructed will determine both what's needed to repair the hole and the length of time involved.

Things You'll Need

  • Waterproof epoxy
  • Patching material (nylon, polyester, PVC, fiberglass)
  • Fine sandpaper
  • Contact cement or vinyl cement
  • Exterior urethane, varnish or paint
  • MEK
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Instructions

  1. Skin on Frame Nylon or Polyester Skin Kayak

    • 1

      Place the boat where it can be easily worked on and in a place with good light. Lightly sand around the hole area where the patch will go. Cut a piece of nylon or polyester to cover the hole and approximately 1 inch more on all sides of the hole.

    • 2

      Carefully apply a thin coat of contact cement to both the boat and the patch. Allow to dry 10 to 20 minutes.

    • 3

      Place the patch over the hole and press firmly all around. Contact cement is forever, so make sure you line it up well before placing the two sides together.

    • 4

      Coat the patched area with several coats of whatever the boat was originally sealed with. This may be an exterior oil- or water-based polyurethane, or an oil- or water-based paint. If you're not sure, go with the water-based polyurethane. It is easy to use and will bond to almost anything as long as you give it a light sanding with a fine sandpaper.

    Wood Strip or Plywood Kayak

    • 5

      Examine the hole area to determine how much the core wood area has been damaged or water soaked. Carefully cut out any soaked or damaged wood.

    • 6

      Cut a piece of wood to match the hole you have removed and carefully place it in the hole. Glue the edges with an epoxy and wood dust mixture. Allow to dry.

    • 7

      Sand any rough spots smooth. Also use fine sandpaper to lightly sand the finish surrounding the damaged area out 2 to 3 inches both inside and outside the kayak.

    • 8

      Cut two pieces of fiberglass cloth extending roughly 2 to 3 inches beyond the damaged area. mix a small amount of epoxy. Apply a thin coat of epoxy over the damaged area and extending beyond, and carefully lay the glass cloth over the damaged area. Then place another light coat over the cloth. When the epoxy has dried, lightly sand and apply another coat. You will probably need three or four coats to fill in the glass weave and achieve a smooth surface.

    • 9

      Lightly sand the finally epoxy coat and cover with a thin coat of spar urethane or varnish. These contain a UV inhibitor to protect the epoxy from the sun.

    Fiberglass kayak

    • 10

      Sand around the damaged area, removing any sharp edges, splinters or rough spots.

    • 11

      Apply a thin coat of epoxy and lay on a patch of fiberglass cloth. Because fiberglass boats are dependent on the glass for their structural core, you will probably need to place two pieces of glass cloth over the patched area. Place the weave of the second patch at a diagonal to the first patch for greater strength. When the epoxy has dried, sand and then add additional coats until smooth, just as you would with a wood-core boat.

    • 12

      Sand the final coat of epoxy smooth and paint or varnish. Matching the paint on a kayak is very difficult, so if you are picky, you may have to repaint the entire boat for a uniform appearance.

    Skin on Frame PVC Skin Kayak

    • 13

      Cut a patch to cover the damaged area and 1 to 2 inches beyond.

    • 14

      Rub the area to be patched and the patch with a light coating of MEK. Allow the MEK to thoroughly dry.

    • 15

      Apply vinyl cement to both the surface of the kayak and the patch. Allow to dry two to three minutes until no longer tacky. Apply patch and rub thoroughly. A heat gun helps activate the glue and gives a faster and more thorough seal.