A: Dents are easy. The plastic that we use has a good memory so putting your kayak in the sun for a few hours will usually cause the dent to pop out. If that doesn’t work, pour boiling water on the dented area and use a blunt object to gently push the plastic into its original shape.
Cracks are more challenging. If you suspect that the crack is due to a manufacturing defect, please contact us for verification. If you dropped your kayak down a cliff, this would be counted as ‘operator error’ and you’ll need to look at making your own repairs.
If you can locate a company with plastic welding experience, try them. If not, you’ll need to attempt the repairs yourself.
Use a small drill to drill into the ends of the crack to prevent the crack from spreading. Clean the crack and even the edges using a sharp blade. To weld the crack closed, you will need some plastic to fill the crack. Cut a narrow strip of plastic from the inside of the cockpit rim (sit-in kayak) or from the inside of the hatch rim (sit-on-top kayak). A plastic welding gun or a heat gun are suitable heat sources as they concentrate heat in a small area.
Start at the beginning of the crack and use the heat gun to heat both the plastic around the crack and the filler piece at the same time. Feed the filler plastic into the crack. You’ll know that your heating is right when the plastic becomes shiny and it sticks easily to the crack on contact. Use a spoon to apply just enough pressure to work the molten plastic filler into the crack and to smooth the surface. Continue heating the sides of the crack and the plastic filler, pushing the filler into the crack, until the crack has been filled.
To level and smooth any areas, heat and apply pressure – do not rub sideways.
Be patient. Work slowly and carefully and take care not to apply too much heat. The repaired crack will never be as strong as the original plastic, but a good repair will ensure that your kayak is watertight again.
DISCLAIMER: Please be very careful when welding your kayak. And don’t blame us if it doesn’t go according to plan.