tomcfitz wrote:
There aren't any "unrepairable" sections on a rotomolded kayak. I just repaired the front of the drivewell crack in my AI, and as a total amateur with a couple beers in me, I had an acceptable repair in about an hour or so. The plastic welding thing is really a lot easier than it sounds, if you can hot glue you can repair any small cracks in the hull.
Personally, after dealing with an old and semi-beat up AI, would estimate my time and effort as:
Replacing all bungies and two broken padeyes: 1 hour, $25 materials
Replacing rudder cables: 2-4 hours. I bet It would take less than 1 if I did it again though.
Trampolines: $500 (Skip it. Hakas are better and cheaper. Don't buy the vinyl ones on ebay)
Lines (furling and main sheet): half hour, tops, and $40ish?
Hull Welding: 1 hour, $82 for the welding kit. Kinda fun, good prep is key. Use the stainless mesh too. There's a youtube somewhere detailing it.
Let us know how long it holds up. I’m very active in some kayak fishing forums and I have NEVER seen anyone simply plastic weld the front drive crack where it held over the long term. Anyone that was successful used a combination of weld; screen reinforcement and highly specialized epoxy designed for bonding HDPE. If you simply welded it with a plastic welder and it holds up under extended pedaling, you will be the first person I’m aware of.