Welding a Plastic Kayak - Crack Repair

Rotomolded polyethylene kayaks are pretty easy to repair. I cracked the area around the scupper after the kayak flew off the car at 60mph (a totally different story). Using just a few simple tools, I was able to repair the kayak. Many people said the kayak was a total loss, especially due to the fact that the damage was done to the scupper--often considered critical. You will need a heat gun, plastic welder, rotary tool with appropriate plastic grinding bit, drill and 1/8" drill bit, and a beer. I purchased both the welder and heat gun from Harbor Freight. The welder was about $15 and the heat gun was similarly priced (bought it years ago). If you crack your kayak, be sure to contact the manufacturer. Often times they will send you the repair material like the welding rod or scrap from other kayaks. You can also check with your local kayak shop to see if they have scrap pieces from other kayaks that you can use to weld the crack with. The only thing that is important with welding your kayak is that you use the same type of plastic to do the welding. This video shows the entirety of the external welding done to the crack. The only thing I didn't show was some internal work I did. I went overbored (the welding was perfectly fine) and lined the repaired area inside the kayak with fiberglass. Totally optional, and really wasn't necessary for this repair.

Welding a Plastic Kayak - Crack Repair sentiment_very_dissatisfied 32

Kayak 12 years ago 138,506 views

Rotomolded polyethylene kayaks are pretty easy to repair. I cracked the area around the scupper after the kayak flew off the car at 60mph (a totally different story). Using just a few simple tools, I was able to repair the kayak. Many people said the kayak was a total loss, especially due to the fact that the damage was done to the scupper--often considered critical. You will need a heat gun, plastic welder, rotary tool with appropriate plastic grinding bit, drill and 1/8" drill bit, and a beer. I purchased both the welder and heat gun from Harbor Freight. The welder was about $15 and the heat gun was similarly priced (bought it years ago). If you crack your kayak, be sure to contact the manufacturer. Often times they will send you the repair material like the welding rod or scrap from other kayaks. You can also check with your local kayak shop to see if they have scrap pieces from other kayaks that you can use to weld the crack with. The only thing that is important with welding your kayak is that you use the same type of plastic to do the welding. This video shows the entirety of the external welding done to the crack. The only thing I didn't show was some internal work I did. I went overbored (the welding was perfectly fine) and lined the repaired area inside the kayak with fiberglass. Totally optional, and really wasn't necessary for this repair.

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Most popular comments
for Welding a Plastic Kayak - Crack Repair

quinnjim
quinnjim - 6 years ago
I was getting ready to purchase a $4,000 Kayak.  After doing some research, I noticed that many of them are cracking.  The fact that this video has 135,000 views means that people are having this problem a LOT.  Maybe I'll just get a regular metal boat...
Jhon T
Jhon T - 7 years ago
Primitive job from primitive hand!
TheSkunkedFisherman
TheSkunkedFisherman - 7 years ago
By any chance do you work on aviation?
Blake Libby
Blake Libby - 7 years ago
This is not welding, its "Melting a Plastic Kayak"
Blake Libby
Blake Libby - 7 years ago
Isaac Miller I don't have it in front of me but when you look at a chart of the fusion reaction of plastics, the best fusion accures just when the plastic becomes molten then steeply declines afterwards. In my opinion, you clearly over did it in this video.
Isaac Miller
Isaac Miller - 7 years ago
by definition, "unite (pieces of plastic, metal or other material) by melting or softening of surfaces in contact."
SwordChux
SwordChux - 7 years ago
Flobots
Lonely Island
MC Chris
MC Lars
Mega Ran
Flight of the Conchords

...I made a playlist just like this lol... kinda freakin me out atm...
claudia williams
claudia williams - 7 years ago
beautiful work
WP Fly Fishing
WP Fly Fishing - 8 years ago
Just today noticed a 2 inch hairline crack in the hull of my Malibu Two & I was shitting bricks. Thanks for putting me at ease. I'm actually kinda looking forward to doing the work on this now.
Christian B
Christian B - 8 years ago
I can ride my bike with no handle bars
6koko3
6koko3 - 8 years ago
How can I get a HDPE welder like the one on this video? May someone help?
steven harvey
steven harvey - 8 years ago
Go to Amazon and just look up plastic welder

10. comment for Welding a Plastic Kayak - Crack Repair

Mike Williams
Mike Williams - 8 years ago
Thank you for this.
THOMAS NELSON
THOMAS NELSON - 8 years ago
MC CHRIS!
mrdilligaf1968
mrdilligaf1968 - 9 years ago
I did mine with a $20 soldering iron with a chisel tip and a output of about 80 watts from Jaycar Electronics. There is a kit where the rod is fed through the middle of the tip but they're expensive. Another thing I found, not all PE plastics are the same. I used the plastic I had left over from cutting a hatch to get the best result.
Dalton Peaslee
Dalton Peaslee - 9 years ago
I bet you could have welded those latex gloves to your hand as well as you welded the kayak.... hehe
benjeboy12
benjeboy12 - 9 years ago
M
G- ortiz
G- ortiz - 9 years ago
Now I learn look how fix... Thx u much!!!!
Love2boat92
Love2boat92 - 10 years ago
Harbor freight drill? I have the same one if it is. Lol.
David
David - 10 years ago
Good video. However, that's filling, it might not hold.
tskfrcdgr
tskfrcdgr - 10 years ago
Someone put this guy on the real nigga roll call. Well done.
somethincreativ
somethincreativ - 10 years ago
Thanks for the upload.  Very informative.

20. comment for Welding a Plastic Kayak - Crack Repair

jadekayak01
jadekayak01 - 10 years ago
this is a soldering iron with shaped tip.plastic welders are usually hot air with a small tip or extrusion or injection welders.
Repair was good but should have left natural(not reinforced) as it may hinder other repairs or additions you might want to make.
Best to overweld and grind back to shape.Bumper repairers use simillar techniques to avoid heat distortion on thin sections
Robert W Blackledge
Robert W Blackledge - 10 years ago
thanks for taking the time to make this video.  rob...
Edward Ferguson
Edward Ferguson - 11 years ago
This is what makes the internet so great. Thanks for taking the time to make this video. Exactly what I was looking for!
metalmanhawaii
metalmanhawaii - 11 years ago
Tote, some people think that the Hobie kayaks are a little thicker than yours, but follow Isaac's video, and you should be fine :) !!! Oh yes...it is DEFINATLY WORTH FIXING :) !!!!
metalmanhawaii
metalmanhawaii - 11 years ago
Harvest: If you do what Isaac did, I don't see why you couldn't do it!! If in doubt, keep a cut-a-way clorax bottle in your canoe for a bailer ;) !!!
metalmanhawaii
metalmanhawaii - 11 years ago
For cracks like that, I prefer to use a heat gun. But looks like you did a VERY good job with that iron :) !!! Cool you backed it up with the fiberglass and G-Flex though to be safe ;) !!! GREAT video and THANKS FOR SHARING :) !!!!!!!!!!!!
Tommy Jensen
Tommy Jensen - 11 years ago
@Isaac Miller Thanks!
Isaac Miller
Isaac Miller - 11 years ago
Between an inexpensive plastic welding iron and West Marine G/flex epoxy, plastic boats are easy to repair!
Tommy Jensen
Tommy Jensen - 11 years ago
Great video! Very informative. I'm considering buying a "Portland Pudgy". It's a sailing dinghy that's rotomolded. I've always had fiberglass boats in the past so I was a little worried about what-if-it-cracks. It's good to know the plastic can be repaired. Thanks for sharing.
Isaac Miller
Isaac Miller - 12 years ago
The manufacturer sent me welding rods for the repair at no cost. It's best to use the same material your boat was made from. Is there an inside edge you could shave some material from?

30. comment for Welding a Plastic Kayak - Crack Repair

jason currie
jason currie - 12 years ago
good video did you use the plastic sticks from Harbor Frieght also or order diffrent ones for the type of plastic the canoe was. i have a small hole in my plastic canoe and every store that i talk too says you cant fix them to just by a new canoe at $400 bucks... lol
rusty keller
rusty keller - 12 years ago
My Brother did this professionally. He'd use the front edge of the air blowing heat gun to heat, melt, and smooth the crack together while feeding in the extra plastic strip. He'd also take several screw drivers and bend, or grind them into different shapes to work the cracks. Mount them in a 2x4 handle down with a propane torch blowing fire across the tips, and they are handy and hot to use. Just grab the one you need for the moment, and the job. The harbor freight melter shown is too fragile.
Isaac Miller
Isaac Miller - 12 years ago
The welding I had to do has held up well, even on a very rough ocean day. The G/flex is awesome and I probably could have done all my repairs with it and skip the welding. I got mine from the local West Marine store (a nation chain) or you can also order it from Northwest River Supply at NRSweb.com. The fiberglass cloth you can find at any autoparts or home improvement store
Larry Koziol
Larry Koziol - 12 years ago
I just saw the post on the fiberglass cloth and g-flex. I read a review on the g-flex and it sounded promising how was it, where did you get it and how much does it cost?
Larry Koziol
Larry Koziol - 12 years ago
Is the weld still holding I have a large crack on salvaged polyethylene canoe from the gunwale down about 8". I'm hoping this will do the trick.
Tote1883gas
Tote1883gas - 12 years ago
Good job mate, Do you know how thick the skin is on the kayak? i have a OK Prowler and it has a few on the face of it "quite deep" scratchs about half way down the bow where the previous owner had dragged it up the beach, Do you think these are worth repairing or filling? Cheers
Dennis Barnes
Dennis Barnes - 12 years ago
Great Job On The Repair. So glad that you were able to save it. and the manufacturer gave you the correct color welding rod.

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