The ELF's body and fender panels are fairly durable and hold up well on regular usage. Typically, you'll get a crack only if you roll it over to the side or run into something (ie crash).
The ELF body is made of thermoformed Trylon (ABS).
Here are some tips from the community: - Whatever you do, be sure to drill crack relief holes at the end of the crack to keep it from traveling. [Davis Carver]
- Organic Transit uses Plexus MA310 Adhesive kit for repairs. [Davis Carver]
- Google search for 'trylon plastic repair'
- You can drill holes and cable tie the split together not a lot of them but larger ties....loosen bolt, tighten cable ties. Once you get them together, I don't know what glue works with this material, may be a super glue gel. [Wm Dan Tracy]
- Maybe put a few holes in it and put some small bolts to hold it all together, plus use some filler to seal the crack. [Dave Altman]
- Contact a kayak repair place. One that rents and repairs sit on top kayaks. I bought used kayaks made out of the same materials and colors. They had been patched underneath for cracks. They don't leak and are strong but the patches are a little messy looking. But then again mine are under the water so no one cares. [Moline Nelson Schrader]
- The Trylon scraps, combined with the appropriate adhesive work really well. I think I used Devcon. [Derek Wilbraham]
- Trylon (ABS) can be repaired by following these instructions. [Popeye]
- Drill a stop at each end of the crack with a 1/8 inch drill bit to prevent the crack from getting worse.
- Clean the area to be repaired with denatured alcohol—NO ACETONE.
- Apply a patch over the entire crack or damaged area.
- ABS material (available from Hurricane) can be used with Devcon Plastic Welder to create small thermoform patches [Popeye]
- Fiberglass cloth and G-Flex Epoxy can be used to create large fluid patches for hard to work areas
- Marine Tex Epoxy Putty can be used to fill voids [Popeye]
- The standard way to stop a crack from spreading is to get the smallest drill bit you have and drill a tiny hole right at the inner end of the crack. It relieves pressure and will tend to prevent the crack from spreading. [Nate Hoy]
- Don't continue to ride...Call OT and see if they are still doing patch kits (scrap Trylon + the right glue) or what they recommend now. [Nate Hoy]
- I have made some repairs with J&B weld for plastics, and it has held well.[Andrew Moss]
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