Posted by: Glenn_MacGrady on Oct-22-12 4:51 PM (EST)
25 years ago people said Royalex tears couldn't be repaired. But there was a guy named Jim Booker, who was a professional welder in the Amherst, MA, area, who had figured out how to weld Royalex rips and tears. He repaired my ME that way -- though the tear was not as bad and multi-directional as yours. He claimed the weld was stronger than the original material, and I never had any reason to doubt that.
Booker used to paddle with the Berkshire Chapter of the Appalachian Mountain Club.
Even if he's not available any more, surely there are other welders who have figured out the process for Royalex.