How to repair a pontoon.

Tube repair

Note: this instruction sheet is for emergency repair of small tears or punctures only. Larger tears or tears which go through a seam will require the assistance of an authorized repair station.

Repair Kit

Tools required: sandpaper, masking tape, glue (no older than 6 months), and wooden or soft plastic stick (size and shape of a ruler, but thicker), and a small paintbrush.

Conditions: the repair must be done in the shade, on a low humidity day.

 Repairs done on direct sunlight when the outside temperature is over 75 degrees Fahrenheit it will not cure correctly.

Step 1: prepare the area to be patched. Mark an area at least 2″ around the puncture or tear. Apply masking tape outside this area, as protection for the surrounding area. Take a piece of medium grade sandpaper, and sand the area to be patched. It should be sanded just enough for the surface hypalon to be rough (you should not be able to see the grain of the underlying cloth!). Check to make sure the surface is evenly sanded.

Step 2: prepare the patch. Cut a patch that exactly matches the size and shape of the marked area on the boat. Any corners on the patch should be rounded. Sand the backside of the patch so it is roughened. Check to see that it is evenly sanded.

Step 3: apply the glue. With the paintbrush, apply a thin coating of glue to the back of the patch, and to the prepared (sanded) area on the boat. Check to see that the entire surface is coated with glue. Let dry completely (about 5 to 10 minutes). Apply a second coating of glue to the patch and to the prepared area on the boat. Let dry until tacky (almost completely dry).

Step 4: apply the patch. Carefully place the patch on the boat. The two surfaces will stick together as soon as they touch, so make sure the patch is applied correctly the first time. Rub the patch with the wooden stick to remove any air bubbles. Place a hard surface under the boat fabric, and use the stick to rub the patch very hard in sweeping movements to push any air bubbles out to the edge of the patch. Rub the patch until the patch is securely fixed to the boat, and there are no loose edges.

Step 5: curing. Your patch must cure for at least 24 hours before inflating the boat or folding the tube.

Step 6: If you think that the area to be repair is too big do your self a favor and call your boat dealer because if  you mess it up the work require to clean your repair will add up to the final bill.