Hole in stern of WS kayak - please help!
Posted by: old_user on Sep-29-12 1:43 PM (EST) Category: Kayaks
So here's the story. My Wilderness Systems Tsunami 160 suffered a drop and the rudder bracket popped out leaving a 1 x 2" rectangular hole. The plastic where the hole is, is about 1/2 inch thick I've posted pictures of the hole at this webpage http://tinyurl.com/98d2ej4
I've been told by a few people to "forget about ever attaching the rudder again." While others say you still can do it if your patch is good and you reinforce it with a steel plate.
So here's the question: what is the best way to patch the hole? Is the best fix a plastic weld with weld rods and a piece of scrap poly. Or can I use a product like G/Flex with some poly or fiberglass? Many dealers have offered repair products, but I've had no luck finding a small piece of actual Wilderness Systems plastic. I worry about getting a good bond.
So I appreciate any advice/photos/experience/videos people can share. I can live without the rudder, but I can't toss this otherwise perfect kayak in the trash. Thanks!
Gedi Convertible Helmet
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i feel like|
Posted by: radiomix on Sep-29-12 3:43 PM (EST)
You could use a piece of aluminum on the inside and a piece of aluminum on the outside. Use a bunch of epoxy to fill the void and reattach the rudder with fastners long enough to go all the way through the new layers of metal.
Posted by: old_user on Sep-29-12 4:41 PM (EST)
I would try|
Posted by: Peter-CA on Sep-29-12 4:21 PM (EST)
I would try. A larger plate in the back (inside), and maybe on the outside, so that the plate overlaps with undamaged plastic could be good. Non-rusting material, like aluminum.
2 metal pieces|
Posted by: old_user on Sep-29-12 4:44 PM (EST)
So how would you connect the metal pieces together and to the boat. Bolts from the inside to out with nuts?
Posted by: Peter-CA on Sep-29-12 8:56 PM (EST)
Yes, bolts. Possibly with the same bolt holes that you have for the rudder.
Posted by: PeaceLoveSandyFeet on Sep-29-12 6:16 PM (EST)
Here's a video showing how to repair the plastic. Chad is a WS legend.
Posted by: LeeG on Sep-29-12 8:30 PM (EST)
Put tape over hole. Put kayak up on end. Mix up 6oz slow cure epoxy with chopped glass. Maybe a couple tbs chopped glass. Plop mess down the hatch into the stern. When cured drill new rudder holes.
Posted by: Andy_Szymczak on Sep-29-12 9:23 PM (EST)
SMALL batches. I tried it with a large|
Posted by: string on Sep-29-12 10:58 PM (EST)
batch(a small cup) and thought I was going to cook the boat. Smokin!
ice it down|
Posted by: edzep on Sep-29-12 11:01 PM (EST)
Put in plastic bag|
Posted by: LeeG on Sep-30-12 5:33 AM (EST)
Then put in bucket w ice.. yr right, too large a batch will boil. It might be necessary to screw a plate of aluminum or ss over the hole anchored to the plug with the rudder mounted through the plate to the plug.
Posted by: sapien on Sep-30-12 7:35 AM (EST)
I would try the metal backing plate with bolts idea, with a layer of plumber's epoxy in between to seal the hole. but first heat up the area around the hole to push the edges down flat.
Posted by: old_user on Sep-30-12 8:48 AM (EST)
Thanks to all for the ideas / feedback. Keep in mind that the reach from the back hatch opening to the repair is nearly 3 ft and it tapers down to an area of about 3 inches x 3 inches. I'm not sure how much I'll be able to do or reach from the inside.
I would do an outside repair, with |
Posted by: ezwater on Sep-30-12 4:04 PM (EST)
a plate strong enough to carry the rudder. I would attach the plate over the hole with both thickened G-flex and with pop rivets. The boat and plate surfaces should be flamed with a propane torch so the G-flex adheres well. The pop rivets are mainly to keep the plate down on the hull and the G-flex while the latter hardens.