Leak in rear crossbar tube, Repair Advice?

I have this problem on two different Hobie Getaways, a 2003 model and a 2022 model.

In both cases, a hull takes on a significant amount of water... I am guessing 25 gallons, enough to drain for nearly 10 minutes.

On the 2003 model, the hull had been replaced with a new port hull a few years ago for the same leak issue. I pressurized this (newer) hull and used soapy water to identify that the leak inside the crossbar tube. I removed the hull, ready to JB weld a plastic crack only to be stymied by the molded-in aluminum sleeve... I gather that these are not meant to be removed, ever. I replaced the hull and tried JB weld around the edge of the crossbeam and tube; this failed and came off.

I bought a 2022 model because I was aggravated with the leak. On my first trip out, no problems. No water in the hulls. Following day, second trip, massive amount of water in the starboard hull. 10 minutes to drain, and... water trickling from the rear crossbar/tube juncture as the hull drained.

What to do? How can a 2-year old Getaway have this issue already? And can it be fixed?

It sounds like you’ve got a frustrating issue with both models. For the 2003 Getaway, it seems like you’re dealing with a tricky spot because of that aluminum sleeve. JB weld might not be the best fix for this type of leak—consider a more robust repair option, like a professional-grade marine sealant or even replacing the entire crossbar assembly if feasible.

As for the 2022 model, it’s disappointing to hear that it’s already showing leaks. Check if the problem is with the crossbar joints or if there might be a defect in the manufacturing. Sometimes a warranty claim could be your best bet if the boat is still under coverage. For immediate relief, reapply a strong marine adhesive around the joints and ensure everything is properly sealed and tightened.

Thanks. I don't think the crossbar assembly itself could be the culprit. I agree about using a marine sealant, the problem is where to apply it, and how.

On the 2022 model, I noticed it has cover/porthole about a foot behind the rear crossbar on each side. They look factory installed, which was a surprise to me. Do Getaways come like this now? Anyway, I can probably use that to apply sealant (probalby 3M 5200) on the inside of the crossbar tube on this boat. I might likewise cut and install an access port on the 2003 model.

I am first going to attempt a lower effort fix by turning each boat on its side, attaching a shop vacuum to the drain hole, and applying liquid marine caulk https://www.amazon.com/dp/B0000AZ8OG?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1&psc=1 around the edge of the crossbar - hoping that gravity and the vacuum will draw it wherever it's needed. On the older getaway, since I don't care as much about the aesthetics and there is no possibility of a warranty claim, I might use the 5200 around the crossbar/hall edge as well (after the caulk cures).