This web site has a lot of information regarding repair of polyethylene and Royalex or Royalite boats. Not all of the links work.
Jim Booker's work is discussed. Links are also given to use of cloth and G Flex for repairs, as well as the ABS/Acetone "paint" method that some have had good luck with (my results were pretty marginal).
Quite a few folks have successfully repaired cracked polyethylene canoes and kayaks using inexpensive thermal welders or even by simply melting PE sticks into cracks with a propane torch. To my knowledge, very few have attempted weld repairs of foam-cored polyethylene or Royalex boats.
Years ago, I was half-owner of a battered Blue Hole Sunburst II canoe previously owned by Carrie Ashton. Someone had "welded" an ABS plate to the bottom of that boat to repair a hole under the pedestal. It looked as if a piece of ABS cutting board had been used, and it certainly didn't look very elegant, but it apparently had been durable. I have no idea what method was used to bond the ABS material to the Royalex or who did it.
If you read through the material regarding the Royalex welding method that Booker used you will find that it involved some pretty expensive stuff. Wasn't a problem for him, since he was a welder by trade. But the average individual who attempts this is probably looking at some significant up-front expenses (although a cheap welding unit sold by Harbor Freight was mentioned that was judged to "probably work") as well as a learn as you go experience. Unless, of course, you are fortunate enough to find someone experienced in Royalex welding repair that already has the equipment. Forget about Jim Booker though, as he doesn't do it any more.
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