Tag Archives: repair

Canoe Repair

Cracks in the hull, minus the moose hoof prints

Prior to heading out to the lake a couple of weeks ago, I had to do some repair work to the hull on my Old Town Discovery canoe. This past winter, I followed moose tracks over to where I had the canoe stored, and found that the moose tried to go through the canoe. I thought it was stored well enough on saw horses, but a moose does what it wants to, and I’m sure it looked like a snow covered log.

There were moose prints in the snow covering the canoe, but it must have realized that it wasn’t a log. If a moose had put all its weight on the Old Town, it would have gone through the hull. As it turned out, the moose only put a few cracks in it. To be fair, the canoe is at least 30 years old, so I have received my money’s worth, but I also like to squeeze every bit out of something I can.

So I decided to repair the hull.

Sanded hull

The first step was to get the canoe in the Rover Hut, then sand the entire hull.

Acetone the hull

I then cleaned the entire hull with acetone. Warning: Acetone should only be used in a well ventilated area**

After the cleaning, I cut alongside the cracks with a razor blade to allow the epoxy I was going to use to get down into the cracks. Then I cleaned the entire hull a second time with the acetone. Luckily, acetone dries extremely quickly.

G-Flex 650 Epoxy

After some internet searching, I found that the G-Flex epoxy was the best product out there to repair the Royalex of an Old Town canoe. I called their tech center to tell them my plan, and get any insight from them. They were incredibly helpful! I received the go ahead from them, and went back out to the Rover Hut. Side note: I did have some down time. The product is not sold in Fairbanks, so I ordered it from Amazon. They promptly sent me a box containing only the epoxy hardener, which is utterly useless by itself.

Filling the cracks with epoxy

Like most epoxies, G-Flex is a two part system. There is a resin Part A, and a hardener Part B. You mix equal parts of both together to get the working epoxy. I mixed up a small batch, and filled the large cracks. The next day, I flipped the canoe over to fill brush some epoxy over the cracks that had come close to coming all the way through the hull.

The hull completely coated in G-flex epoxy

Because of the canoe’s age, there was a fair amount of what I would describe as “spider-webbing”. A series of tiny cracks that had not gone through the hull, but had probably made it easier for the moose to cause the large ones. I wanted to coat the entire hull in the epoxy to at least buy me some time with the spider-webbing. Luckily, the G-Flex went on rather easy with a brush, and spread out in an even coat.

The epoxy can be top coated, although I have not done so. Krylon Fusion spray paint is said to work well on Royalex, but again, I have not attempted that.

The Discovery back on the water

The end result: The old canoe was back on the water, and glided just like it did when I bought it. No leaks, and the epoxy didn’t scare away the lake trout.