PREP Your boat has to be clean before you begin work. Hose it down and then sand or scrape the surface around the repair area. Opening up the crack a little with a scraper will help with the binding process. Finally, clean the area inside and out with mineral spirits as dirt and grease can interfere with welding.
THE FIX Whether you’re working on a deep gouge or a crack, the process of heat- ing and mixing is more or less the same. Dors says holes are rare, “but if you’re this unlucky, you’ll have to find a scrap piece of poly, cut it to size and follow the same process as welding a crack.” Begin by preheating the material. If your hull didn’t crack on its first run
down the river, then its surface is probably fuzzy and whitened. “You’ll know the surface is hot enough when it starts to get shiny and the fuzzi- ness disappears,” Dors says. If you’re using a heat gun, you’ll also need to preheat the welding rod. When welding with a heat gun, lead with the gun and follow with the
heated rod. Keep the gun one to two inches away from the work surface. Mix the welding rod with the boat material using a stirring motion so as not to let the melted plastic pool. A steady, methodical hand will do the trick if you’re using a welding iron.
Just take your time, ensuring the material mixes well, and leave the rest up to the iron. If you’re using reinforcement, support the hull and realign the crack, then
press the mesh or rod into the plastic as you heat. Allow the plastic to mix around the reinforcement for strength. “If it doesn’t mix well, the weld will pop open when it cools or is under stress,” Dors cautions. Taking your time will ensure the heat penetrates the material and mixes it com-
pletely. “Don’t rush,” coaches Dors, “plastic does not conduct heat well.” Continue the weld at least a half-inch beyond the length of the damage. This will prevent cracks from continuing to form after welding. “The weld should be just as thick or thicker than the original surface of the boat,”
says Dors. Reheating the area until its pliable and gently pressing it back into shape with a flat, metal object can smooth out lumps.
“THE WELD SHOULD BE JUST AS THICK OR THICKER THAN THE ORIGINAL SURFACE OF THE BOAT” —Jamie Dors
32 RAPID SPRING 2011
Prepping the crack.
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