Hypalon Adhesive – How to repair inflatable boat tubes made from hypalon

HYP-pro-kit-guide72Materials needed:-
• P510 Hypalon Cleaner & Solvent
• 2 part Hypalon Adhesive
• Paint brush (cut down to
20-25mm bristle.)
• Lint free cloth
• Hypalon material
• Masking tape
• Polythene
• 60 grit Sandpaper / emery cloth
• Rubbing Down Smoother

(Image: Polymarine Professional Repair Kit for Hypalon Tubes, plus Polymarine ‘Smoother’ tool.)

Before you start any gluing please note:- your workplace needs to be well ventilated, warm and dry. If the air is humid don’t try to use the adhesive as it will bloom. Do not use a gas fire or naked flame heat source as the solvents are highly flammable. Do not use the adhesive if it has been mixed for more than 4 hours.

This full page is available as a PDF download

Mix adhesive with Curative at the ratio of 25:1
The Curative supplied is in ratio with the adhesive, so half the curative and half the tin will also be 25:1

If the damage to your tube is more than 75mm in any direction an ‘inside patch’ needs to be applied. The procedure is the same as for an Outside Patch but is made more difficult because you are working on the inside of the tube.

1. Mark out and cut your material to size. This should be big enough to cover the damage plus 30mm on every side.
Make sure that all the corners are rounded.

sand2. Sand down the top surface on the patch until it is lightly abraded to a matt finish and the back surface of the tube is sanded until the surface starts to break up and looks like suede. Wipe the surface of the patch and the tube that is going to have the adhesive on with the P510 solvent cleaner. Allow the solvent to flash off (evaporate). If you apply the adhesive to soon it will bloom (turn slightly white) the adhesive will need to be removed and new adhesive will have to be applied.

3. Mix half of the adhesive (2990 two part adhesive) as directed on the tin. Brush onto the surface thinly, the surface should look wet. Allow the adhesive to dry for at least 30 minutes.

pushup4. Apply second coat of adhesive to both surfaces, Leave until tacky to the touch (5 to 15 minutes). With the inside patch lay a piece of polythene onto the adhesive, so it can be rolled up and put through the hole. Place inside the tube and put into position, remove polythene. Work one side down with your Smoother, pressing hard, then work the other side. Work from the middle to the outside of the patch. You must make sure that there is no air trapped between the surfaces. Please note:- the adhesive is a contact type, as soon as it touches the other surface it will stick. Make sure that the patch is in the correct position before the surfaces come into contact.

5. Leave to dry for at least six hours.

6. When dry, pump up the chamber and check for air leaks. The inside patch must be air tight.

brushon7. With the tube inflated prepare the outside of the tube and your outside patch. Using masking tape around the patch leaving about a 3mm gap to allow for stretch in the material.

8. Sand down the surface of the tube until it is lightly abraded to a matt finish, and sand the back of the patch until the surface starts to break up and looks like suede. Wipe both surfaces with P510 solvent cleaner. Mix the rest of the adhesive. Apply first coat of adhesive, leave for 30 minutes, apply second coat of adhesive. Leave until ‘tacky’ (5 to 15 minutes).

rubdown9. Put down the patch and rub down from the centre out with your Smoother. Check that all the edges are stuck down.
You must make sure that there is no air trapped between the surfaces. Remove the tape and rub off any excess adhesive with P510 solvent cleaner. If the adhesive is left on it will turn brown.

10. Leave to dry for at least six hours before putting pressure in the tube.
Full cure 48 hours. Maximum Bond Strength 7 days.

D Ring Patches & Accessories

Rubber, Hypalon and Neoprene accessories
can be glued with Hypalon Adhesive using a similar technique to the patch repairs.

1. Sand the surface of the Hypalon Inflatable where the accessory is to be glued until it is lightly abraded. Sand the accessory if Hypalon or Rubber (Don’t sand PVC).

2. The surfaces of the inflatable & accessory should be cleaned with the Hypalon Cleaner & Solvent to remove any trace of finger oils or dust.

3. Paint both surfaces to be adhered with a thin coating of glue. Allow the adhesive to dry for at least 30 minutes.

4. Next spread a second thin layer of adhesive on both pieces and leave 5 to 15 minutes until the surface is tacky to the touch.

5. Bring both together with as much pressure as possible. Rub the air out with Smoother. You may want to deflate the boat to assure a better bond for the accessory. It is critical to get all the air out from between the pad and the surface of the inflatable, and the pad is sealed completely around the edges.

6. Once the air is out from under the accessory, let it cure for 48 hours. Max bond strength 7 days.


  1. where can we get the Rubbing Down Smoother

  2. Will this bond to wood or do I have to coat the wood with something?

  3. Hello, yes, all of those methods would work to remove old hard adhesive; Polymarine P510 Solvent (which contains MEK amongst other things). A heat gun or hair drier to soften. Sanding with care not to damage the Hypalon.

  4. Hi,
    We repaired our hypalon dink and I stupidly inflated the tubes a touch which caused a starfish of air escapes under the patch. We noticed the air escapes and that it would not hold air 24 hours later.
    Rather than attempt to inject more adhesive, we removed the patch, which has left gummed and hardened residue of the adhesive. What would you recommend we do to prepare to re-patch? Possibly solvent (mek, acetone etc?), heat gun and scrape, light sanding or other.
    Thanks in advance

  5. Hi Darryl. At your soonest convenience, you can remove the repair and the pvc adhesive using Polymarine P510 solvent for Hypalon. If the patch and adhesive is cold and stiff, using a hot air gun might help to soften the adhesive and patch – BUT make sure your solvents and flammables sealed and well away from the hot air gun.

  6. Help! I have done a stupid thing…I used Polymarine PVC kit to repair 4 holes in my Apex hypalon dinghy..(long story how this happened)…will the patches hold? And for how long? What should my next step be?

  7. Is it possible to effectively use this adhesive in high humidity? I live in the tropics and cannot control temp/rh.

    Mixed up a 75 mL batch with 3 mL catalyst in ~80F, 80%RH. Pot life approx 45-60 mins before completely gummed up. Could not apply thin coats with brush. Past tacky in <5 mins after application.

    Can I add toluene to the mix to thin for application without effecting adhesion? Could I use less catalyst to increase working time?

    Any advice would be appreciated. Paying shop repair fees is not an option.

  8. Hello David, Humidity above 65% could cause blooming. If you think humidity is high, make a test application and see if it blooms. Good ventilation usually eliminates a humidity issue.

  9. Directions say “workplace needs to be …warm and dry. If the air is humid don’t try to use the adhesive as it will bloom…”
    – how warm?
    – what is allowable humidity?
    garage workspace is air-conditioned, usually 75 degrees F (can make warmer but humidity might increase)


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