How to repair and replace the rudder pedal support flanges on a thermoformed ABS kayak

How to repair and replace the rudder pedal support flanges on a thermoformed ABS kayak

This article and attached file with video walks you through the steps to replace and install new flanges to attach your kayak pedals to in a thermoformed ABS kayak for Boreal Design or Riot Kayaks. 

Tools Needed:
  1. Tape (any will do but suggest painters tape for easy on and off)
  2. Sandpaper
  3. Electric sander or grinder
  4. Sharp knife
  5. Cleaning cloth
  6. Gloves (optional)
  7. Phillip Head screwdriver
Parts Needed:
  1. Flange (M5 or M6 - both sizes will work)
  2. Hardware (phillips pan head screw)
    1. M5 - SKU: 15006
    2. M6 - SKU: 16028
  3. ABS glue (suggest 2-part waterproof metal / plastic epoxy).  Something to this on Amazon

  1. Tape the pedals to one side so that they do not interfere with the sander operation

  2. Use sander to smooth out broken flange

  3. Roughen the back of the new flange with sandpaper

  4. Inject a ring (full amount) of ABS glue on the back of flange, stick it on the original position of the flange, and press it slightly to fix it in position (Pay attention to alignment to prevent any deviation

  5. Clean up any ABS glue around edges with a cloth

  6. Tape the flange in place to prevent it from moving while glue hardens.

  7. Remove tape once hardened and then you are ready to mount the pedal foot tracks with screws

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