G'Day NTG,
Ann and I were in a similar position with a 16 y.o. Hypalon
Zodiac a few years back. Once the outer Hypalon has worn through and exposed the
fabric scrim layer inside, sun
rot weakens the scrim to the point that painting is useless, no matter how super the paint is. We used various patching materials scrounged from other defunct dinghies, bladder type
water tanks, even some PVC based Herculite
fabric (stuff used for pool covers, patio stuff and so on). We tried a lot of different glues. As mentioned, the typical Bostic stuff
sold for Hypalon repair (and used in the manufacture of dinghies) has a very short shelf life and is expensive. Either Sikaflex 291 or 3M 5200 works quite well, though holding large patches in place long enough for curing is touchy. Using techniques like this we got another couple of years out of "ZOD the magnificent"!
At any rate, I bet that you can find someone else's dead inflatable somewhere in
Fiji and dissect it for patch material. IF you are gonna use Sika for
adhesive, PVC material will
work ok (if it isn't too dead itself).
IF you can obtain 2-part
polyurethane foam in
Fiji, filling the tubes with such has been successful, but it can be a bit exciting to
work with. And of course, you can't deflate the tubes then!
Finally, getting new tubes put on does work. We had our nearly new Gemini RIB stolen in Hobart a few years ago. The sods drove it up the Derwent to their lair, removed the 12 Y.O. beater Suziki o/b, poured petrol into the hull and lit it off. The police eventually found the charred corpse and we got her back. The powder-coated alloy hull was scorched but intact, and after a lot of work
cleaning it up we returned it to the Gemini folks in Southport. They put new tubes on for just one half the
price of a new dink. Prior to that, an independent
dinghy repair chap had said that he could fabricate new tubes as well, but never got a
price from him.
So, there's hope for you... good luck with the job, and we hope that your bum stays dry!
Cheers,
Jim