LIP GRIPPER
A HEAT GUN, PLASTIC WELDER, SANDPAPER
AND MATCHING PLASTIC WILL FIX ALMOST ANY DAMAGE TO A
POLYETHYLENE KAYAK. CLEAN THE AREA WITH
RUBBING ALCOHOL AND ROUGH UP THE PLASTIC WITH SANDPAPER.
USING A HEAT GUN,
HEAT THE AREA UNTIL THE PLASTIC IS SOFT
AND MALLEABLE. IT WILL APPEAR GLOSSY.
USING THE HEAT GUN TO
KEEP THE DAMAGED AREA HOT, MELT THE PATCH ONTO THE REPAIR AREA
USING A PLASTIC WELDER. PHOTOS: RIC BURNLEY
[R IGG ING]
PLASTIC PATCH UP K
ayak anglers are tough on their boats. Dropping, dragging, banging, bouncing,
rocking and rolling are all part of the game. Fortunately roto-molded kayaks are nearly indestructible. Even if one happens to get damaged, polyethylene plastic can easily be repaired. The job requires only basic tools and a few simple skills. Just heat up the plas- tic, melt in a new piece, and sand it smooth. Like a phoenix, a plastic kayak is wrought from fire and from fire it will rise again!
TOOL TIME
As with any job, the right tools are the key to a successful final result. They are readily available; purchase them online or at a well- stocked hardware store. The two most im- portant implements are a plastic welding rod and a variable temperature heat gun. For big repairs, a piece of stainless reinforcing mesh fortifies the patch. A rasp and some 400 grit sandpaper will prep and clean up the repair. For the best results, order matching plastic from the manufacturer. If you don’t need very much, trim a piece from inside a hatch rim. Be sure to wear heat resistant gloves and eye protection. Use a pair of long-nose pliers to hold the hot plastic.
TURN ON THE HEAT This project depends on heat. Polyethylene plastic softens at 100 to 120 degrees. Past
26 …KAYAK ANGLER SUMMER/FALL 2012
HOLEY KAYAK? FIX IT YOURSELF IN FOUR EASY STEPS BY RIC BURNLEY
135 degrees, the plastic starts to melt. To achieve the perfect temperature, use a plastic welding rod and a heat gun. The welding rod is designed to hit the optimum temperature for melting plastic. Fit the heat gun with a re- ducing nozzle and it will direct a stream of hot air to the plastic. Before getting started, wash the kayak and thoroughly clean the area to be patched. This job really requires three hands. To make things easier, have a buddy help out. First, heat the patch and the damaged area until both pieces of plastic turn waxy and start to sweat. Continue to apply heat to the hull with the heat gun. Have your bud- dy hold the patch plastic against the kayak while you use the welding rod to melt the two pieces of plastic together. To fill a large hole, add stainless steel mesh between the repair plastic and the hull. Work from the outside of the crack to the center building up layers of plastic. Finish off by using the heat gun and welding rod to spread and shape the patch.
FINISHING TOUCH Let the plastic cool until it is hard. Check the strength of the repair by trying to pry the patch off with a flat-edge screwdriver. Rough shape the plastic with a rasp, then finish with sandpaper. Use the plastic welder to smooth out any irregularities. Fill the kayak with wa- ter, let it sit for a few hours and then check for leaks.
IN CASE OF
EMERGENCY... There I was, miles from anywhere, and my kayak was sinking. Luckily, I pack an emergency repair kit.
PLASTIC FIRST AID KIT • 8 oz. tube Marine Goop • Waterproof tape
FIX-A-FLAT
1. Thoroughly dry and clean the damaged area.
2. Place a piece of tape on the back of the hole.
3. Fill the hole with Goop. 4. Allow 30 minutes to dry. 5. Test for leaks before continuing.
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