Highlander AirTrek: patch and repair guide

Every Highlander ships with a patch repair kit. The 6-step procedure uses AQUASEAL® glue and acetone (or M.E.K.) to bond a patch over the cut or puncture. Cure the glue with the board un-inflated for 24 hours before use. If the leak is at a seam, file a claims form instead — that's a warranty case, not a field fix.

Every Highlander ships with a repair kit in the bag — patch material, glue, and applicator. Small cuts and punctures are a field-repairable scenario using the procedure in the User Manual. Seam separation is not a field fix — that's a warranty case.

This procedure is sourced from the Highlander User Manual. Download the printable PDF (link below) for the full version with illustrations.

When to patch yourself vs. file a claim

Issue	Action
Cut or puncture in a drop-stitch panel (top, bottom, or sides)	Field patch using the procedure below
Slow leak from valve seat	Clean the valve (sand/salt in threads) — fixes 80% of slow-leak reports. Not a patch case.
Seam separation (visible fabric pulling apart at a glued seam)	File a claims form — this is a warranty case
Damage from puncture but pressure won't hold even after patching	File a claims form with photos + the patched location
Damage you caused (rocks, dragging, etc.)	Field patch — this isn't covered under warranty

Supplies required

Your repair kit ships with the patch material and applicator. You'll need a few common items not in the kit:

Glue: AQUASEAL® (recommended) — included in repair kit
Acetone or Methyl Ethyl Ketone (M.E.K.) — for cleaning the area
Hairdryer — for heat-curing the bond
Brush — for applying glue evenly
Tape — for outlining the patch area (prevents glue spread)
Spatula or spoon — for pressing out air bubbles under the patch
Towel — for wiping cleanup

6-step procedure

Step 1 — Clean the area

Clean the area around the cut or puncture using acetone or M.E.K. to remove any contaminants. The bond won't take on a dirty surface.

Step 2 — Outline the patch

Draw the outline of the patch using chalk or pencil (do NOT use ink — it can bleed through). Cut the patch to cover the cut or puncture with approximately 2.5 cm (1 inch) overlap on all sides.

Step 3 — Tape the perimeter

Apply tape along the outline of the patch. This prevents the glue from spreading outside the patch area and keeps the bond cleanly contained.

Step 4 — Apply glue

Apply glue on both the board and the patch using a brush or other applicator. Make sure the glue is spread evenly and completely over the board and patch.

Let the glue dry for 1 minute.

Step 5 — Apply the patch

Apply the patch starting on one side and move towards the other side. Be careful not to trap any air bubbles under the patch — they'll cause the patch to fail.

Step 6 — Heat-bond and press

Use a hairdryer to gently heat the area to ensure a good bond between the patch and the board. Use a metal spatula or spoon with firm pressure to ensure a good bond and to remove any air bubbles.

Cure: 24 hours, un-inflated

Allow the glue to cure with the board un-inflated for 24 hours prior to use. Inflating before the cure completes will pull the patch off the board.

After the patch

Once the cure is complete:

Inflate slowly to 8-10 psi and inspect the patch visually.
Let it sit for 30 minutes and check pressure with a digital gauge.
If pressure holds, gradually inflate to full operating pressure (12-15 psi).
If pressure drops, the patch hasn't bonded fully. Re-do the procedure from Step 1 — possibly with more careful cleaning or a fresh tube of glue if yours has set up.

If the patch fails twice

File a claims form. The User Manual specifies that damage from punctures isn't covered under warranty, but if you're encountering a patch that won't bond despite proper technique, we want to look at the panel — could be a fabric defect at the puncture site.

What's NOT covered under the inflatable warranty

The 2-year inflatable warranty does not cover damage from:

Punctures (covered by your patch kit, not warranty)
Excessive heat exposure
Improper handling and storage
Use in waves or shore break
Board breakage caused by filling or crashing in surf conditions
Any damage other than defects in material and workmanship

Seam separation, drop-stitch failure on a properly stored board, or material defects from the factory are warranty cases. Patches are for everything else.

Download the full PDF

The Highlander User Manual contains the patch procedure with illustrated steps.

[PDF download link will be populated once the manual is uploaded to Shopify Files.]