How Do You Fix a Crack in a Kevlar Canoe?

Kevlar canoes are popular among paddlers due to their durability and lightweight construction. However, accidents do happen, and it’s not uncommon for a Kevlar canoe to develop cracks over time. Luckily, fixing a crack in a Kevlar canoe is a relatively straightforward process that can be done at home with the right tools and materials.

Step 1: Assess the Damage
The first step in repairing a crack in your Kevlar canoe is to assess the damage. Look closely at the crack and determine its size and location.

If the crack is small and located on the hull or deck of your canoe, you may be able to fix it yourself. However, if the crack is large or located near a seam or structural component of your canoe, it’s best to take it to a professional for repair.

Step 2: Gather Your Materials
To fix your Kevlar canoe, you’ll need a few materials:

  • Epoxy resin
  • Hardener
  • Fiberglass cloth
  • Sandpaper (80-grit)
  • Paintbrushes
  • Safety gear (gloves, goggles)
  • Plastic wrap

Step 3: Prepare the Area
Before you start repairing your Kevlar canoe, make sure that you’re working in a well-ventilated area with plenty of space. Lay out plastic wrap on your work surface to protect it from any spills or drips.

Next, use sandpaper to rough up the area around the crack. This will help the epoxy adhere better.

Step 4: Apply Epoxy Resin and Fiberglass Cloth
Mix together epoxy resin and hardener according to the manufacturer’s instructions. Then, using a paintbrush, apply a layer of the epoxy mixture over the crack.

Cut a piece of fiberglass cloth that’s slightly larger than the crack and lay it over the epoxy. Use a paintbrush to apply another layer of epoxy over the fiberglass cloth, making sure to saturate it completely.

Step 5: Let It Cure
Once you’ve applied the first layer of epoxy and fiberglass cloth, let it cure according to the manufacturer’s instructions. This usually takes several hours, but can vary depending on temperature and humidity.

Step 6: Sand and Repeat
After the first layer has cured, use sandpaper to sand down any rough spots or excess epoxy. Then, repeat Steps 4 and 5 until you’ve built up several layers of epoxy and fiberglass cloth over the crack. Each layer should be slightly larger than the previous one to ensure a strong repair.

Step 7: Finish Up
Once you’ve built up enough layers of epoxy and fiberglass cloth, let your canoe cure for at least 24 hours before using it again. After curing, use sandpaper to smooth out any rough spots or excess epoxy. You can also paint over the repair with a matching paint color if desired.


Fixing a crack in your Kevlar canoe is easy with just a few materials and some patience. By following these simple steps, you can have your canoe looking as good as new in no time! Remember that safety comes first when working with chemicals like epoxy resin – always wear gloves and goggles when handling it.

Photo of author

Michael Allen