Repair of Whitewater Boats using Plastic
Welding and other Techniques

Plastic Welding for repairing whitewater boats is a well-known, but not well documented skill. Hopefully these pages will help you along in that regard.

Whitewater boating is hard on equipment. Many boaters commonly use duct tape, glue, kevlar patches, and/or fiberglass to repair damaged boats.

However the best repair material is always the same material the boat is made from. For most boats this means ABS (Royalex, Royalite, R-84) or HDPE plastic.

ABS and HDPE are thermoplastics, meaning they get softer as they heat up. And they can be welded with the right equipment. The web pages below some some examples of plastic welding, the equipment required, and hopefully give you a few hints on how to repair your boat. (Note: This is not a commercial site, we're not trying to drum up business. As a matter of fact, we'd prefer to be on the river and the intent of these web pages is to enable other paddlers to repair their own boats so we don't have to.)

Questions/comments/brickbats/accolaides to: Skip Morris (morris@skip.net).

Enjoy...

Jim Booker welding an ABS patch to the inside of a Dagger Rival.

Photo (c) Mark Lacroix.

Introduction and Overview

   Introduction and background.
   Equipment used.
   Types of plastic and whitewater boats.
   Cements, glues and other repair materials (future).
   Basics of plastic welding (future).

Complete Repair Examples - Start-to-finish step-by-step.

   Delamination repair on hull, outside patch only (Mohawk Probe 12).
   Severe delamination, both inside and outside patching (Dagger Rival).
    (Above example is more detailed, but picture quality is marginal... sorry...)
   Gunnel repair, replacing a shattered damaged gunnel section (Mohawk Probe 12).
   Using Plasti-Mend ABS Repair Kit [under construction].

Other Repairs - Overview only.

   Hole patching, filling a hole punched thru the bottom hull (Dagger Encore - Skip's first repair).
   Bow reinforcment on a punched-in bow/stern (Dagger Rival) with flat ABS stock.
   Wrapped boat repair, putting a boat (Mad River ME) almost torn in two back together.
   Hairline crack repair on the hull (various boats).
   Letting the sun do the work on a wrapped crosslink kayak.

Other Resources.

  Video—How to fix your carbon kevlar, or carbon fibre boat.
  Plastic Boat Welding 101 from Liquidlogic
  Ken Glusman's experience making and using ABS paint from Legos.
  Bill Blatner's notes from discussion with Spartech Engineer.
  Notes from discussion with Spartech Engineer on glues and ABS putty, June 2009.
  Archived NERIVERRUNNERS thread on boat repair.
  Repairing a Royalex Canoe with West System G/flex Epoxy.
  Gluing plastic with West System G/flex.
  Seelye web page describing the features and applications of different types of plastic.
  This machinedesign.com page gives insight to the chemistry of plastics.
  Physical properties of plastic piping page from Chemical Engineering cheresources.com.
  Page from University of Sea Kayaking by Shawn Baker on boat construction
  Prof. Stephen Collins welding links page .
  Welding bolt page from kayakoutfitting.com.
  Adhesive ordering page from kayakoutfitting.com.
  Working with plastic pipe from doityourself.com.
  Repairing cracks in crosslink boats with WhaleyWelding.
  Mark Cumnock's Plastic Welding Services for boat repair in the S/E.
  International Plastics page on welding cements.
  StarLoc Industrial Adhesives page (Poly-Weld and other products).
  Laramy Products sells welders, tips, and plastic rod.
  Seelye, Inc. in Florida sells welders, tips, and plastic rod.
  Seelye Plastics in Minnesota manufactures plastic equipment & components.
  Malcom Hot Air Systems sells welders, tips, and other supplies.
  V & A Process, Inc, sells all sorts of welding rod.
  How to weld page from Seelye.
  Plastic welding hints from Malcom Hot Air Systems.
  Plastics Magazine article on welding.
  Plastics Magazine article on weld failures.
  Misc information on Kydex, a PVC related plasic used in foot pegs, etc.
  Commercial plastic welding training from PWS in Rhode Island.
  Plastic welding rods available from Abbecon Cal, Inc.
  Book, video, other supplies from Delvie's Plastics, Inc.
  PWT sells plastic welding tools, rod, etc.
  Canoe Outfitting from Canoe Kayak and Paddle Co. [no long avail]
  Jack's Plastic Welding, Inc.
  River Connection (com)
  Front Royal Canoe (links)
  OceanKayak.com's tips on repairs.

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Pictures and Text (c) 2002,2009 SWM.