KAYAK MAINTENANCE and REPAIR

I. Southern Nevada Paddling Club KAYAK INSPECTION Fiberglass, Kevlar and Plastic
opposite side of bulkhead or hull for water drops. Cockpit Coaming Cracks and chips. Hanging Seats 1. Elliptical screw holes. 2. Loose or worn screws. 3. Worn seat parts. Foot Braces and Rails loose screws and wear Deck Rigging weakness, wear, or damage General Hardware loose or damaged. Carrying Handles & Loops - wear or damage. Painters (Bowline) - wear or damage. The following should be fully inspected once each year. Visual inspection of all surface items every three months. A. Hatch covers Gaskets and rubber seals. B. Rudder Cables 1. Remove screws at cable ends inspect cable and screws for wear. 2. Check for frayed sections along cable length. C. Rudder Assembly - Remove Screws and inspect all parts for wear. D. Bulk Heads 1. Visual Loose or cracked caulking 2. Water leak test - pour 1 quart to gallon of water into section. Place kayak at an angle so water is against the bulkhead, then inspect

E. F.

G. H. I. J. K.

II.

KAYAK GENERAL MAINTENANCE - Fiberglass, Kevlar and Plastic

A. Hull Maintenance 1. Cleaning - Use a mild soap and water. 2. Hard water stains White vinegar and water solution, 30 percent vinegar to 70 percent water. Place solution in a spray bottle and apply on small area, wipe clean with paper towel or soft cloth. 3. Waxing/Polish Use a good quality marine Wax/Polish. 4. Ultraviolet (UV) protection spray deck and hull with 303 Protectant. This product is also good for spray skirts, PFDs and etc. 5. UV Hull Damage Use a rubbing compound to remove chalky surface. Then apply a Marine polish. Finish by applying a coat of 303 Protectant. B. General Maintenance 1. Clean Foot Pedal/Slide Bar Track with high-pressure hose. Wipe Track and slide bar with paper towel or cloth. Caution: metal parts may have sharp edges. Apply Tri-Flow or Super Lube dry lubricant on Foot Pedal/Slide Bar Track. 2. Clean cockpit interior with high-pressure hose. Remove all mud and small pebbles. 3. Every two to three trips lubricate rudder assembly.

III.

KAYAK GENERAL REPAIR - Fiberglass, Kevlar and Plastic

A. Bulkhead Caulking 1. Remove all old caulking (clean and repair one side at a time). Clean surface with scraper, sand paper, then alcohol. 2. Use 3M Marine Adhesive Sealant 5200, 10 fl oz. Use a caulking gun and apply in sections of approximately six to eight inches. Place kayak at a slight angle so adhesive flows towards bulkhead. Adhesive tends to cold flows, rotate hull to control direction of flow. When first section is stable complete caulking of the next section. This material takes approximately 48 hrs to completely cure. 3. When the first side has fully cured, then repair the opposite side of Bulkhead. B. Rudder Cables 1. Apply a light coating of Tri-Flow or Super Lube dry lubricant (do not use a silicone base lubricant), use a Q-tip or small rag, to areas of the cable that makes contact with metal parts or cable channels. C. Foot Pedal and Rails 1. Use masking tape and tape a double thick layer of paper towel on the hull under each end of the Foot Pedal/Slide Bar and Track. This will catch dirt and lubricant drops. Author: Milton D. Rasmussen Page 1 of 5 Revised: September 7, 2002

Recommended book for repair and Maintenance: The Essential Outdoor Gear Manual, Annie Getchell, Ragged Mountain Press.

KAYAK MAINTENANCE and REPAIR

Southern Nevada Paddling Club
2. 3. 4. 5. 6. 7. D. 1. 2. 3. 4. Remove Foot Pedal/Slide Bar from Track clean both with steel brush and/or stiff toothbrush. Wipe Track and slide bar with paper towel or cloth. Caution: metal parts may have sharp edges. Use emery paper or small mill file to remove sharp edges and burrs from Foot Pedal/Slide Bar and Track. Clean the Track groves with a dry Q-tip. Spray a Q-Tip with a small amount of Tri-Flow or Super Lube. Then wipe each grove in the Track. This will remove additional dirt from the Track. Do not spray Tri-Flow or Super Lube directly into the Track Spray the foot pedal/slide - back, front and edges with a thin film of Tri-Flow or Super Lube dry lubricant. Spread lubricant with a Q-Tip Insert Foot Pedal/Slide Bar into the Track. Move Foot Pedal/Slide Bar back-and-forth in theTrack to spread lubricant. Rudder Assembly Use a wrench and screwdriver to remove rudder from mount. Clean assembly parts. Use emery paper or small mill file to remove sharp edges and burrs from Rudder parts. Apply Tri-Flow or Super Lube dry lubricant to metal parts that make metal-to-metal contact. Replace all worn parts and screws. Then reassemble.

E. Hanging Seat 1. Remove seat and inspect screw holes. If holes are elliptical there are three methods for repair. a) First Clean and fill hole with an epoxy Place a washer on both sides, and then patch, then redrill the hole. install a screw through the center hole, b) Second - Drill a slightly larger hole and which will also hold the seat. insert a metal sleeve (spacer) of correct size c) Third -Drill a new mounting hole in a and length, with a hole through its center. different place if necessary. F. Hatch Covers 1. Cleaning - Use a mild soap and water to clean hatch cover and around lip of hatch (coaming). 2. Spray Armor All on all rubber or neoprene hatch covers parts (not on Kayak hull or deck). Wipe of excess with a paper towel or cloth.

IV.
1. 2. 3. 4. 5. 6.

REPAIR TOOLS AND MATERIALS

Masking tape, inch wide. Emery PaperMill File (fine tooth file) Q-Tips Screw Drivers, as required Wrenches, as required Tri-Flow (Sherwin-Williams) or Super Lube. (Synco Chemical Corp., www.super-lube.com) Sources: Hardware, Home Depot, and Auto Parts stores. 7. 3M Marine Adhesive Sealant 5200, 10 fl oz tube. (Source: Home Depot). 8. Caulking Gun 9. Armor All. Source: Auto part stores (Armor All Products, Irvine, CA). 10. 303 Protectant (303 Protectant Inc. Paleo Cedro, CA). Source: Home Depot. 11. Rubber Gloves.

V.

GENERAL KAYAK REPAIRS - Fiberglass and Kevlar

This section is limited to Gelcoat repairs (surface and cosmetic) and will not cover extensive repair of hull penetration or fracture of Fiberglass or Kevlar materials. It is recommended that the manufacturer repair hull penetration damage.

A. Kayak Hull Repair Fiberglass and Kevlar

Gelcoat repair can be accomplished with a minimum of materials and tools. It does however require that specific procedures be followed. The following material can be used in surface repair of Gelcoat.

Author: Milton D. Rasmussen

Page 2 of 5

Revised: September 7, 2002

Recommended book for repair and Maintenance: The Essential Outdoor Gear Manual, Annie Getchell, Ragged Mountain Press.

KAYAK MAINTENANCE and REPAIR

Southern Nevada Paddling Club
1. Kits and Repair Materials A. Epoxy Patch Kit (select one type) a) Evercoat Marine Match and Patch, Gelcoat Repair Kit, No. 668. Source: West Marine. Includes 6 color pigments. b) Sea Fit, Gelcoat Repair Kit, SEAFI No. 105192 (model # 140251). Source: West Marine. Includes 6 color pigments. c) Marine-Tex, Mfg: Travaco. Trvco # 133884 (model # 140251). Source: West Marine plus Marine and Auto Parts stores. Note: Long term tests have proven this to be a short-term repair. Material tends to flake away after several months. Most repair kits come with instructions for mixing the epoxy resin and hardener (catalyst) use rubber gloves when handling materials. Follow the health warnings, these materials can cause skin and eye irritation plus respiratory irritation. B. 1. 2. 3. 4. 5. 6. 2. A. B. Repair Materials Squeegee Sandpaper, 320, 380, 400, 600-grit. Backing pad for sandpaper Rubbing compound Clear plastic sheet - approx. 2 to 3 mil thick Masking tape, or 1 inch wide. 7. Spatula (Ice cream stick), for mixing and applying material. 8. Alcohol, Denatured 9. Plastic coffee can lid or similar material. For a mixing dish 10. Rubber Gloves.

Gelcoat Repair Surface Preparation Remove any cracked or flaking gel coat material. Lightly sand repair area to remove fading and oxidized materials. Bevel edge of scratch or gouge to improve adhesion of repair epoxy patch. Clean the patch area with Denatured Alcohol. Be careful not to touch work area with bare hands. Epoxy and Color Test Use a plastic coffee can lid or similar plastic piece to mix epoxy material on. Place a suitable amount of epoxy and hardener on plastic surface and mix. Be sure to completely mix all material. Separate the mixed epoxy material into three equal parts. a) Apply the colored pigment onto one sample section. Add pigment until color match appears to be correct and of the recommended amount. Mix completely. Spread out one edge of the sample until it is thin. Clean spatula. b) On the second test sample section apply approximately 20 percent more pigment than the first test sample. Mix completely. Spread out one edge of the sample until it is thin. Clean spatula c) Leave the out the third sample section without any pigment. Allow all test samples to cure. Every few minutes test the surface of all epoxy samples for the following: a) The usable work time. The point where the material can not be applied or spread. b) The cure time. Where the material is hard and can be sanded or polished. After the samples have completely cured. Check manufactures recommendation. a) Check the unpigmented sample for hardness and flexibility. It should be hard and brittle. b) The first pigmented test sample should also be hard and brittle. You may find that the color sample may have very little color in the thin section of the sample. c) The second pigmented test sample should also be hard and brittle (sample may be slightly more flexible than fists sample). You will find that this color sample will have improved color density in the thin section of the sample. If the sample is soft and flexible then there is too much pigment or not enough hardener in the epoxy. Select the best sample for use in the final repair.

C. Epoxy Hull Repair After you have identified the epoxy mix and color ratio; mix a suitable amount of material to perform the hull repair. Do not mix too large of an epoxy batch for use. Note: a large batch of mixed epoxy generates heat, reduce work time, Author: Milton D. Rasmussen Page 3 of 5 Revised: September 7, 2002

Recommended book for repair and Maintenance: The Essential Outdoor Gear Manual, Annie Getchell, Ragged Mountain Press.

KAYAK MAINTENANCE and REPAIR

Southern Nevada Paddling Club
and in very large batches can burn. You will have approximately 5 to 10 minutes to complete all work before the epoxy starts to setup. Work in very small repair sections. Large section may not give you enough time to complete all required work. Apply a thin layer of epoxy into the damaged area that is to be repaired. Place a clear thin plastic sheet over the epoxy patch material. Spread the epoxy material that is under the plastic sheet with a squeegee. Run the squeegee along the line of the scratch or at a 45-degree angle, not across the scratch. Use masking tape to hold down the plastic sheet until epoxy has cured. A small sandbag (approx. 1 lb.) may be place over the plastic sheet to provide equal pressure across the repair surface. Leave until the epoxy has cured. D. Patch Finish Caution: avoid breathing the sanding dust. Peel off the plastic sheet. If required sand patch area using 320 to 380-grit paper with a backing pad. Next sand with 400-grit paper and backing pad to remove scratches.

Finally sand with 600-grit paper with backing pad. Use rubbing compound to finish surface. Polish as needed.

E. Repair Through Holes in Deck Use a 60-degree screw camber tool on the front and backside of hole. Do not go very deep. Note: This will help to conceal the repair and prevent the repair plug from moving. Place a piece of masking tape on the underside of the hole. Make sure that epoxy will not flow through the patch. Inject material in to the hole until full. Perform epoxy repair as described in the above article. Finish the top surface as described in the above article. The surface underneath only requires the removal of any sharp edges.

VI.
A. 1. 2. 3. 4. 5. 6.

KAYAK TIPS - Fiberglass and Kevlar

Storage Tips Store kayak in garage or under a cover to reduce Ultra Violet (UV) damage to kayak hull and deck rigging. When storing the kayak - remove all hatch covers to dry out the compartments. Place kayak on a form fitting hull cradle or suspend on web belts, 1 to 2 inches wide. Place cradle or belts at or near Bulkhead area. This is the strongest area of the hull. Storing kayaks on one side of hull also works well. Release all tie down belts, lines or life lines that may put stress on deck fittings, which may cause stress cracks in jell coat. If the rudder has an elastic pull down line, lower the rudder during storage to reduce damage to elastic line.

B. Transport Tips 1. Do not tighten holding straps excessively. This can cause Gelcoat cracking and excessive pressure on fabric lamination can cause material to delaminate. 2. Use a bowline tied to car bumper or other car parts to reduce bow lifting. On long kayaks also use a stern line to prevent kayak rocking and reduce hull damage. Also on long trips use a stern line on all kayaks. 3. When carrying more than one kayak tie a line between the kayaks, both bow and stern, this reduces rotation by side wind thrusts. 4. Stow all handles and deck line ends to prevent damage to kayak deck. Wind may cause banging of parts on the deck surface. 5. Lock down the rudder in the stowed position to prevent vibration during transport.

VII.

KAYAK HULL REPAIR Polyethylene Plastic

This section is also limited to surface repair and maintenance of plastic hulls. Hull penetration repairs should be performed by the manufacture. Author: Milton D. Rasmussen Page 4 of 5 Revised: September 7, 2002

Recommended book for repair and Maintenance: The Essential Outdoor Gear Manual, Annie Getchell, Ragged Mountain Press.

KAYAK MAINTENANCE and REPAIR

Southern Nevada Paddling Club
A. Hull Surface Blemishes Removal of surface blemishes such as plastic hairs and scratch ridges these can be removed by a safety razor or small wood plane. B. Hull Deformation 1. Hull Dents - Remove hull dents by heating area with a heat lamp or hair dryer gun, then press on inside of hull to return hull to original shape. Caution: do not over heat hull surface. A small beanbag or sandbag placed on inside of dented area while heating outside of hull also works. 2. Hogged Remove reversed hull curve (Hogged Hull) by hanging kayak by its carrying handles or on wood blocks with hull side down. Works best during hot summer days. Adding a five-pound sandbag inside may help.

VIII. KAYAK TIPS - Polyethylene Plastic

A. Storage and Tips 1. Store kayak in garage or under a cover to reduce UV damage to hull and deck rigging. 2. When storing kayak remove all hatch covers to dry out the compartments. 3. Place kayak on a form fitting hull cradle or suspend on web belts, 1 to 2 inches wide. Place cradle or belts at or near Bulkhead area. 4. Storing kayaks on side of hull or on deck for plastic boats, reduces hogging and denting of hull. 5. Manufactures often store plastic kayaks by standing them on end. B. 1. 2. 3. 4. 5. Transport Tips Do not tighten holding straps excessively. This can deform the hull and change Tracking, especially in summer. Do not leave plastic kayak tied tightly on car tops for long periods during summer days. This may deform the hull. Use a bowline tied to car bumper or other car part to reduce bow lifting. On long kayaks also use a stern line to prevent kayak rocking, this can reduce hull damage. Also on long trips use a stern line on all kayaks. When carrying more than one kayak tie a line between the kayaks, both bow and stern, this reduces rotation by side wind thrusts. Do not pull down excessively on lines, which may cause hogging.

IX.
1. 2.

FIELD EMERGENCY REPAIR - Fiberglass, Kevlar and Plastic

Pierced Hull Duct Tape or Epoxy putty stick on inside and outside of hull. Rudder Cable breakage Several methods. a) Splice short section of cable into rudder cable using material from emergency kit. b) Use a short piece of rope to join broke cable. c) Replace the broken cable using material from emergency kit. Rudder Assembly Use Nuts and bolts from emergency kit.

3.

X. EMERGENCY REPAIR KIT 1. 3M Duct Tape, type 131 (1.88 in wide by 10 yd.) and Epoxy stick or putty (Primex of California, Ding Stick Kit). 2. Alcohol swabs - individually prepackaged 3. Spare screws, washers nuts and bolts1. 4. Screw drivers Phillips and common blades, as required for your kayak. 5. Vice-grip pliers and common pliers 6. Multitool knife 7. Spare rudder cable and swages. 8. Rudder Cable cutting tool. 9. Bungee cord 10. Galvanized wire
1

11. Adjustable wrenches or set of open-end wrenches, as required for your kayak. 12. Rope, or 3/8 inch, 20 ft long. 13. Sand Paper 320 or 380 grit 14. Sharp Knife.

Select size and type to fit your specific kayak. Author: Milton D. Rasmussen Page 5 of 5

Revised: September 7, 2002

Recommended book for repair and Maintenance: The Essential Outdoor Gear Manual, Annie Getchell, Ragged Mountain Press.