wetsuit repair - applying a neoprene patch

[harbour seal]

Hello good people of Deeper Blue,

I finally managed to repair my barnacle ravaged wetsuit! See my earlier post for details on the attack: http://forums.deeperblue.net/freediving-equipment/73415-barnacles-ate-my-wetsuit-please-help-repairs.html

I am going to put up some step-by-step pictures of the process, which might aid others in future repairs.

Cheers,
Sean
Vancouver, Canada

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I first emailed photos of the damage to elios, the makers of my wetsuit. Here are the instructions i received:

Hello,
we have seen the photos and you can put a piece of thinnest neoprene 1/2mm to cover the part.
perfect will be a 1,5mm open cell inside to stick over the suit / nylon outside.
you can use also a classic neoprene glue in this method:
>1) clean both parts with alcool
>2) spread a first film of neoprene glue on both sides
>2) wait two hours without stitching together
>3) spread a second film of neoprene glue on both sides
>4) after 5 minutes stick together
>
>This method will make the work better and without other problems!
Best regards



NOTE: The barnacles ripped the nylon covering, in the process damaging the neoprene underneath (in the armpit area); however, the wetsuit was not torn all the way through.




http://i51.photobucket.com/albums/f3...y/IM002271.jpg

[harbour seal]

ANOTHER REASON TO LOVE ELIOS (eliossub website Home) :

Not only do they make sweet wetsuits but.....I did not have the recommended neoprene patch materials so they offered to send me some. Within a week i received a selection of fabric peices (no charge).




http://i51.photobucket.com/albums/f3...y/IM002278.jpg

[harbour seal]

List of materials:

- isopropyl alcohol
- scissors
- can of neoprene glue
- small paintbrush
- fabric marking pencil --- use rounded tip on fabric (similar to coloured pencils)
- clean-up rags (not pictured)



http://i51.photobucket.com/albums/f3...y/IM002284.jpg

[harbour seal]

First clean wetsuit by soaking in fresh water. Let dry thoroughly (at least 1-2 days).

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Before cutting a neoprene patch, first create a proper-sized paper template of area to be covered (see photo below).

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Cut neoprene patch using your template.

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Next clean all surfaces to be glued with alcohol and (clean) rag. Allow to dry.

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Place patch on damaged area. Then using a fabric pencil lightly trace around the patch. These markings are a guide for applying the glue.



http://i51.photobucket.com/albums/f3...y/IM002276.jpg

[harbour seal]

Apply first coat of glue to both neoprene patch and damaged area. There were 2 small tears outside the patch area which i also coated with neoprene glue. Allow to dry 2 hours.

Note: If you look closely you can see the light blue markings on the wetsuit around the glued area.



http://i51.photobucket.com/albums/f3...y/IM002277.jpg


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The nylon fabric seemed to completely soak-up the first coat of glue, thus i decided to add an additional coat to all surfaces. If there had not been an outer nylon layer on my wetsuit, this additional coat would not be necessary.

Apply second coat of glue. Allow to dry 2 hours.

---

[harbour seal]

Apply final coat of neoprene, then wait 5 minutes (or slightly less).

Stick patch onto damaged area (while glue is still tacky).

Firmly press patch into place with fingers. Next apply a (flat) weight onto patch to provide constant pressure. Wait 10 minutes and firmly repress patch area with fingers. Re-apply weights. Wait 2-3 hours.

Remove weights and firmly repress patch area with fingers. At this point your are basically finished.



http://i51.photobucket.com/albums/f3...y/IM002278.jpg

[harbour seal]

(Optional added step)

The patch was now well adhered, but the squared-off edge stuck out above the surrounding wetsuit. I worried this raised edge might easily catch/tear and be susceptible to damage. I decided to attempt to glue the bare neoprene side-edge of the patch down onto the surrounding nylon surface of the wetsuit. The goal was to round the nylon outside edge downwards and smooth it out.

I painted a 3 mm wide coat of glue immediately surrounding the patch (using a small paintbrush). I also coated the bare neoprene side-edge of the patch itself. Wait 1-2 hours.



http://i51.photobucket.com/albums/f3...y/IM002279.jpg

Apply another layer of glue. Wait 1-2 hours. I also added a few more coats to the small tears outside the patching area (see photo).

Appy a final coat of glue. Wait 5 min but glue should still be tacky when sticking surfaces together.

Press-down the side-wall of the patch onto the surrounding neoprene --- continue pressing and holding for 10 minutes.

Note: I first did only the top half of the patch edge, before adding glue to the rest. Once the first half was finished, stuck-down and dry, i repeated the process on the other half of the patch.

The result was the edges of patch were now (mostly) rounded-down --- it is hard to see but for the most part it worked.

Neoprene glue reaches full-strength after 24 hours.



http://i51.photobucket.com/albums/f3...y/IM002282.jpg

[harbour seal]

Operation sucessful! Finished product:



http://i51.photobucket.com/albums/f3...IM002282_1.jpg

[harbour seal]

Final Notes:

- If you have not used it before, neoprene glue remains wonderfully supple and extremely flexible even once it is dry (very different from aqua-seal).

- Use a well ventilated room---this glue produces lots of fumes. I cracked the patio door and turned on a fan after I started to get a head-rush.

- Consider trimming some of the neoprene right along the edge of the patch; make the cut at a sharp angle rather than squared-off straight perpendicular edges (the patch should taper from narrower to wider towards the outside edge of the patch). This would help the patch lay flatter on the wetsuit surface once glued down. My concern was the patch might not be as durable if i thinned out the neoprene materials along the edges; however, my patch ended-up sticking out above the wetsuit surface along the edges (as i described earlier).

- I probably should have used a slightly thinner piece of neoprene, as elios suggested in their directions (1 to 1.5mm). They sent me a few different thicknesses with nylon-out and open-cell-in. I chose a thicker piece (approx 3mm ?) for 2 reasons: 1) the nylon side matched my wetsuit pattern---fashion first, baby--- and 2) i figured a thicker piece might be more durable as it was hard to tell exactly how deep the original damage went.

- If the wetsuit is torn all the way through then a different approach might be required, including sewing the suit back together. Best to email photos to your suit makers and get their expert opinion. Also take a look at this thread from a few years ago by jon http://forums.deeperblue.net/wetsuits/37449-wetsuit-repair.html


A day later, on close inspection my patch seems solid and feeling around from inside the suit with my hands I can't feel the presence of the patch at all. Additionally, the glue on the small tears seem like it will prevent any further damage to the area.

I will report back after diving.

Dive safe and barnacle free,
Sean

[atomichaggis]

If you have not used it before, neoprene glue remains wonderfully supple and extremely flexible even once it is dry (very different from aqua-seal).

Aqua-Seal is a brand that makes many products. I use aqua-seal 'seal cement black' to repair My open cell surface and it is plenty supple.
The distinction You need to make is between the various products. Neoprene cement (clear, classic, yellow) for nylon coated surface repairs (patching) and Black neoprene cement for open cell surfaces.

[harbour seal]

hey davie,

thanks for the heads up!

let me be more specific, i am refering to AquaSeal Repair Adhesive & Sealant.




http://i51.photobucket.com/albums/f3...Macoy/acc5.jpg

[atomichaggis]

That stuff is notoriously stiff tho it can be ok for patching onto Nylon.

[harbour seal]

Originally Posted by atomichaggis

That stuff is notoriously stiff tho it can be ok for patching onto Nylon.

for that very reason i would avoid using it on a wetsuit at all, even on a nylon-covered side.

applied to any type of wetsuit fabric, including nylon-covered, it won't allow stretch/movement and will likely cause damage to the fabric directly surrounding the patched area in the long run. especially bad in any area that undergoes stretching/movement.

a few years ago, i tried patching a big tear in the neck of a wetsuit hood i used for surfing with aquaseal repair and adhesive sealant. once dry, the patch held but ripped the fabric alongside the patch. unfortunately for my hood, back then i had not yet heard of using neoprene glue for repairs.

cheers,
sean