Repairing small damaged areas

Instructions for carrying out a simple repair to Hypalon Fabric

Required Materials:

Hypalon Tube Material
Seam Roller
Thinners or Acetone
Latex Gloves
Eye Protection
Sandpaper (80 grit)
Lint Free cloth

Safety First:

Always work in a well ventilated area.
Latex gloves, eye protection and a Respirator are highly recommended.


There are several different types of boat damage that will result in the need of a patch. The example is a 2" long cut which requires a patch on the outside. A tear in the fabric 12"+ will require a patch to be placed on the inside and out. An internal and external repair will need to be treated like two separate repairs, allowing the first to cure before adding the second.


Step 1: Cut the Hypalon Tube Material patch to extend 2" from all sides of the damaged area. The patch shown is approximately 4" x 6" for the 2" long cut. Round all the corners - round corners do not catch and peel as easily as square corners


Step 2: Trace the area of the patch with a pencil


Step 3: Buff with sandpaper all the areas to be glued; the traced area on the boat and the underside of the patch piece. Buff off the traced line to ensure that all the borders are prepared for gluing. While buffing, a chalk-like dust will appear. Buff until this chalk-like substance no longer appears as a result from buffing. The buffed area should end up as a dull version of original colour. Do not buff down to the threads.


Step 4: Clean the buffed surfaces with a lint free towel and either Thinners or acetone

Step 5: After the surfaces (damaged area on the boat and the underside of the patch pieces) have dried from the cleaning step, apply a very thin layer of adhesive to both surfaces

Step 6: After the first layer of glue is just beyond tacky, apply a very thin second layer of adhesive to both surfaces. Test for "just beyond tacky" with a gloved finger or by touching knuckles to the glued area. The glue should feel gummy, but should not stick to the gloved finger or knuckles. Do not use a bare finger, otherwise oil will be left behind. Drying times vary due to the different temperatures, humidity and the use of the hardener

Step 7: Adhere the surfaces after the second layer of glue is just beyond the tacky phase. Be careful with this step. Make sure to place the patch in the correct area. Hypalon adhesive is a contact cement, so once the surfaces have contacted they cannot be removed.

Step 8: Once the two surfaces are pressed together, apply pressure with the seam roller. Focus on the centre of the patch and work outward. Roll every millimetre of patch in multiple directions. This step is important because it forces air bubbles out and helps the two pieces of fabric to bond


Step 9: Use a towel and thinners or acetone to wipe up any excess glue that was expelled from the patch edges whilst rolling.

Step 10: Allow the patch to cure. Curing times vary due to the different temperatures, humidity and the use of hardener. The optimal repair environment of above 15°C and below 50% humidity, allows for a curing time of 72 hours