To repair cracks in plastic kayaks and canoes, use plastic cleaner solvent to remove grease or other contaminants. Align the edges if the boat is cracked, and hold it in place by duct taping the damaged place. If a drill is not available, heat the end of the drill bit with a torch, holding the bit with vise grips, and melt the hole at each end of the crack.
The function of the hole is to clean the damaged area with mineral spirits to remove wax, oil, or other contaminants. Use 60-80 grit sandpaper to scratch the surface around and a little bit beyond the repair. Flame treat the plastic surface.
Before fixing a hole in your kayak, look up your kayak’s brand and model online to see if it is made of crosslink or linear polyethylene. If it is crosslink, you cannot heat, sand, fill, or repair the damage. Sand the edges of the patch and the edges of the hole.
Some people use a grinder for the patch to make things go faster. Put on gloves (provided in the kit) and mix up some epoxy per the directions. There is an inexpensive way to repair holes and cracks in a kayak and other thick plastic material using a plastic welder stapler.
Work slowly heating the damaged edges of the break, not melting all the way through the kayak. Be gentle and let the tool do the work. Use a spoon or screwdriver to smear the epoxy into the groove. Sand or trim off any excess to make the repair smooth.
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