DIY: Overhaul A Kayak, Part 1: Repairing Oyster Rash and Removing Rust

On my last trip out with the kids to catch sandbass, it was abundantly clear that they had outgrown riding in my Wilderness Systems Commander 120. We made it work with them on the captain’s perch and me in the low seat, but it was much more crowded than when they were younger.

My solution? Find an older model tandem on the used market and rig it for my needs. I was lucky enough to find some folks getting rid of a first-generation Native Ultimate 14.5. Here is what I was dealing with:

The Good

• Spray Skirt on Bow

• Upgraded Rudder Kit

• Seat fabric in great condition

The Bad

• No track system

• Worn out shock cord throughout the rigging

• Mediocre Rod Mounts (and generally poor layout of accessories for my style of fishing)

• Good bit of rust and rash from the salt

• Poor drainage design

This post is Part I of a multi-part series focused on how I overhauled the kayak. Every step can be applied to any polyethylene kayak you may be converting for fishing. This first post focuses on removing oyster rash and rust to restore the hull to tip-top shape.

Materials Needed

• Bar Keeper’s Friend

• Fiberglass Pen

• Bernzomatic Propane Torch

• Metal Spoon

Step 1: Clean the Bottom of the Hull

Wash down the bottom of the hull to get as much dirt off as you can. This will make for a cleaner repair. [00:32]

Step 2: Heat Up and Repair the Gouges

Using a propane torch, heat up the polyethylene hull while keeping the torch moving to melt small slivers back into the cracks. Using a metal spoon—lubricated with saliva to prevent sticking—work the gouges closed and smooth them out. The goal is a smooth finish to reduce drag, not necessarily a "factory-new" look. [00:46]

Step 3: Remove Large Rust Stains

Wet down the large rust stains and sprinkle Bar Keeper’s Friend on them. Scrub the rust off with a coarse cloth or a brillo pad. This works well for stubborn stains that even a pressure washer can't touch. [02:12]

Step 4: Remove Rust Stains in Hard-to-Reach Places

For hard-to-reach rust, such as rings around screws you don't want to remove, wet the area and use a fiberglass pen to loosen the grime. Follow up with a scrub of Bar Keeper's Friend to finish the job. [03:17]

Wrapping Up

Stay Tuned: Part II – Installing Flush-Mount Rocket Launchers for Trolling. In the next part, I’ll show you how I replaced the standard flush mount rod holders with Scotty Rocket Launchers to keep the kids in the action while we're moving between spots.