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Inflatables are susceptible to heat and over-pressurization... and heat causes over-pressurization too. Inflatable products using glues are subject to glue degradation and failure from age and heat. This is an issue across the board with other companies. There are restrictions on better (but toxic) glues (EPA) I believe and this can limit the choices companies can use. Our product is unique in that we also have a well that the materials have to bond to. No mechanical connection should be required.
I don't believe my kayak has had a problem with over-pressurization. I highly suspect that the failure with the bubble is due to the folding and unfolding of the kayak, due to the location of the bubble, that has caused a small leak in the inner material. Seeing now that there are at least two of us with a similar issue with the same year Hobie, I have to wonder how many more Hobies of this year are experiencing the same issue.
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Unlike rotomolded and thermoformed products, inflatables can degrade just sitting in storage as the glue materials age and succumb to heat. 5 years depending on conditions and level of use is actually pretty good. I have been to the Caribbean and seen mountains of inflatables that have failed in use by charter companies.
We're not talking about charter use in the Caribbean, but rather limited recreational use in the Upper Midwest. I have a Sea Eagle Kayak as well that has no issues, that I purchased at the same time. I know of others with various inflatable kayaks and dinghy's that have lasted well over 10 years. The Hobie Kayak listed for $2200+ at the time of purchase. I believe an inflatable kayak of that expense should have a life expectancy when well cared for, for more than 5 years.
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Inflatables offer many advantages in weight, storage, and transport space required... but they do have limitations in lifespan. One of the reasons the warranty on inflatables is less than on other products.
I'm learning that...
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We don't do repairs here at our facility, but there are companies that do in many areas of the country. I would contact those kinds of people (if your dealer is not able to help) for the best help in handling a repair.
Do you know of any companies in the Midwest that would do this kind of repair. Or do you have any recommendation on what the repair should compose of. I'm considering cutting around the bubble, finding and patching the leak, and then re-gluing the outer material back down. OTOH, if this is just a cosmetic issue as long as the bubble doesn't expand, I can live with that. But if I have a situation developing like the poster above, where the kayak would not hold air, or could start leaking while in use, then I believe it would be unsafe to use it.