DIY Drysuit Latex Gasket Repair: A Quick, High-Quality Fix on a Budget
Who knew the latex on my drysuit could tear? Any time off the water is no fun, so here is what I did to fix it fast!
The core of this DIY project lies in assembling a custom repair kit using affordable, easily sourced materials and following a precise, methodical approach to repair. Here's how to make your repair kit and execute the repair, ensuring your drysuit is ready for your next adventure.
10” acrylic disc, resin tape and wax paper. I always have resin tape and wax paper around for board and boat repairs. The Aquaseal will not adhere to the Resin tape.
Assemble the DIY Repair Kit:
Latex Neck Gasket: Opt for a quality latex neck gasket found online, which matches the specifications of your drysuit for a snug fit. I got mine from Amazon.
Acrylic Disc: A 10" diameter, 1/4" thick acrylic disc serves as a stable base for the repair process. Sourced from Amazon.
PVC Rings: 10" diameter PVC rings designed for light fixtures can be adapted to hold the gasket in place during the repair. Cut these in half and trim to fit the curvature of your drysuit's neck. Sourced from Amazon.
Aquaseal+Neo: A versatile adhesive suitable for latex repairs, ensuring a durable bond and quick curing time. Sourced from Amazon.
Double-Sided Tape: Essential for positioning the gasket correctly and preventing it from moving during the repair process.
Wax Paper and Tape: To wrap the acrylic disc, facilitating easy removal after the adhesive cures. Tape sourced from Amazon.
Other Essentials: Include a sharp razor knife for precise cuts, sandpaper to roughen the contact surfaces for better adhesive bonding, and clamps to secure everything in place while the adhesive cures.
These are trim collars for light fixtures.,10”. I cut them in half with tin snips and made them more narrow.
I mistakenly trimmed the collar too tight on my first try. Basically you want the new neck to mate with the new gasket on the INSIDE of the suit. So here I’ve trimmed up to the edge of the fabric, leaving an inch of the old neck on the inside.
Detailed Repair Process:
Prep the Suit: Wash your drysuit on a delicate cycle and air dry thoroughly, turning it inside out to ensure both sides are completely dry.
Trim the Neck Gasket: Carefully cut the damaged neck gasket down to a 1" overlap. This will be the area where you attach the new gasket.
Prepare the Acrylic Disc: Wrap the acrylic disc in wax paper secured with tape to prevent the adhesive from sticking to it. This disc will act as a form to shape the neck gasket during the repair.
Secure the Disc: Use double-sided tape to attach the disc to the inside of the drysuit, aligning it with the area where the new gasket will be attached. This step is crucial for alignment and ensuring a smooth repair surface.
Apply Adhesive: After preparing the surfaces with sandpaper, apply a generous amount of Aquaseal+Neo to both the drysuit and the new latex gasket. Carefully place the gasket over the adhesive, ensuring it's perfectly aligned.
Clamp and Cure: Use clamps around the edge of the gasket to press it firmly against the suit. The more clamps, the better the bond. Allow the adhesive to cure for at least 24 hours.
Finishing Touches: Once cured, remove the clamps and acrylic disc. Apply a thin layer of Aquaseal around the edges of the gasket for a clean, waterproof seal.
Stretch and Fit: Gently stretch the repaired neck gasket to ensure it fits comfortably. This may require a temporary form, like a quart paint can, to expand the gasket to its proper size.
I always have wetsand light sandpaper on hand for board and boat repairs also. Just light etch the latex to help with the bonding of the Aquaseal.
Wrap the clamp template with the tape. This was easier than using the wax paper on this part.
Fit the 10” acrylic disc, wrapped in wax paper, inside the neck. Have the double-sided tape in a ring around the neck to hold the old gasket in place. It was a pain to get the top of the double-sided tape off, but I found that a razor knife did it fairly easily. This is Gorilla Tape. It worked ok.
Aquaseal. I had black on hand from wetsuit repair. Research proved it was just as good as the clear. Smear this stuff around so it coats the old neck latex.
Mate the new neck to the old INSIDE OUT. I used a piece of tupperware to hold the narrow neck up so the bellow stays out of the way of the clamp. This clamp set cost $10 at Home Depot. Use all of them! Then leave it alone for at least 24 hours.
Getting Back on the Water:
Inspect your work for any gaps or weak spots in the seal. If everything looks solid, your drysuit is ready for action. Remember, this repair, while durable, should be checked periodically, especially before heading out on challenging waters.
Conclusion:
This DIY approach to drysuit latex gasket repair not only saves time and money but also empowers you to maintain your gear in top condition. With these steps, you're not just fixing a tear; you're ensuring that your adventures on the water can continue without interruption.
Engagement:
I hope this guide demystifies the process of drysuit repair and encourages you to tackle future gear maintenance with confidence. If you've found this post helpful or have additional tips and experiences to share, please leave a comment below. Your feedback enriches our community and helps all of us stay safer and drier on the water.
Looks professional! This was not easy but like everything in life, I’m now empowered. Kit will stay in the repair kit box for the rest of my days. I’m sure I’ll have to do it again…
Don’t forget to stretch the new neck gasket. I also had to trim the new neck, following the trim lines on the gasket.
Back on the water!