Bicycle Water Pack Leak Repair

So the hydration pack I’ve been using for a few years started piddling all over the floor, whereupon some debugging revealed a pinhole leak where the large thermally sealed flange meets the bag side. Nothing, but nothing adheres to the polyethylene (or some such) bag material, but a blob of acrylic caulk (armored with a layer of electrical tape, not shown) may suffice for a while.

Hydration pack leak repair blob
Hydration pack leak repair blob

I did the same thing to the other side as a prophylactic measure…

7 thoughts on “Bicycle Water Pack Leak Repair

  1. I was able to fix an HDPE chicken waterer base with hot glue. I first drilled a series of 1/8″ holes right down the crack, about 3/8″ on center, then applied the glue liberally from both sides so it flowed through the holes, Still holding and watertight after a summer of use :)

    1. That’s funny; reminds me of a plastic toy car that my Dad fixed for my brother. Cracked bottom that no glue would stick to. He drilled a series of holes, stitched it up with 16 gauge bare copper wire and used hot melt glue to hold it all together! The repair outlasted my brother’s interest int he thing. Didn’t have to be water tight, but looked like a Frankenstein wound stitched up.

      – Steve

      1. I did use string string through the some holes at the ends of the cracks that intersected the edge, then slathered those with hot glue like like all the others.

        So it has a bit of Frankenstein look at the ends :)

        Did your dad grow up on a farm? That sounds like a farm fix ;)

      2. The repair outlasted my brother’s interest

        That’s the definition of a successful repair: works for as long as you need it, doesn’t cause any bad side effects.

        The Quality Shop Time comes as a bonus…

    2. drilled a series of 1/8″ holes right down the crack

      See, now, that’s the spirit: “We have a leaky container. Let’s drill a bunch of holes in it!”

      Maybe it’s a general rule, along the lines of “It’s gotta get worse before it gets better…”

  2. If I remember correctly, polyethylene is normally repaired by welding, using either rods or patches. I believe it’s possible to do it with amateur means as well (i.e. without using an ultrasonic heater), using a torch or soldering iron. Never tried it myself though.

    Then again, if the caulk holds, it should do the trick as well.

    1. polyethylene is normally repaired by welding

      I actually have a hot-air plastic welding setup with a few hours of power-on time, but using it on a flexible bag seems fraught with peril. The last time I tried using it, I converted a crack in a polyethylene trash can into a rather hideously slagged hole; obviously, I need more practice.

      I’m hoping the caulk remains flexible enough to stick, with the tape protecting it from being peeled off. So far, so good …

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