Welding a Plastic Kayak - Crack Repair

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Rotomolded polyethylene kayaks are pretty easy to repair. I cracked the area around the scupper after the kayak flew off the car at 60mph (a totally different story). Using just a few simple tools, I was able to repair the kayak. Many people said the kayak was a total loss, especially due to the fact that the damage was done to the scupper--often considered critical. You will need a heat gun, plastic welder, rotary tool with appropriate plastic grinding bit, drill and 1/8" drill bit, and a beer. I purchased both the welder and heat gun from Harbor Freight. The welder was about $15 and the heat gun was similarly priced (bought it years ago). If you crack your kayak, be sure to contact the manufacturer. Often times they will send you the repair material like the welding rod or scrap from other kayaks. You can also check with your local kayak shop to see if they have scrap pieces from other kayaks that you can use to weld the crack with. The only thing that is important with welding your kayak is that you use the same type of plastic to do the welding. This video shows the entirety of the external welding done to the crack. The only thing I didn't show was some internal work I did. I went overbored (the welding was perfectly fine) and lined the repaired area inside the kayak with fiberglass. Totally optional, and really wasn't necessary for this repair.