How to Repair a Wetsuit: Step-by-Step Guide

Neoprene is not a particularly tough material. It tears easily against a sharp rock, a hook, a nail, or any other pointed edge encountered in the water or on the shore. Most wetsuits have a nylon jersey covering bonded to the neoprene on one or both faces, and this jersey layer absorbs some of that surface damage before it reaches the neoprene underneath. Triathlon wetsuits are a common exception: to reduce drag and improve flexibility, many are made with minimal or no jersey coverage, leaving the neoprene exposed. The thin neoprene on these suits is particularly easy to pierce with a fingernail when pulling the suit on, which is one of the most common ways triathlon wetsuit damage happens.

Seams fail differently. Factory wetsuit seams use a glued and blind-stitched construction. The stitching does not go all the way through the neoprene, which keeps the suit watertight but means the seam bond line can be worked open by repeated movement and water ingress. Once a seam begins to separate, each session in the water extends the split further.

Neoprene Queen Contact Adhesive is a solvent-based contact adhesive formulated specifically for neoprene. It cures by fast evaporation of the solvent, which means it reaches 70% of its full bond strength within five minutes of pressing the surfaces together. This makes it well suited to beach-side repairs where you need to get back in the water quickly. Full bond strength is achieved in 24 hours.

What You'll Need

• Neoprene Queen Contact Adhesive
• Isopropyl alcohol and clean cloths
• A matchstick or small brush for narrow areas
• Flat work surface
• Neoprene patch material (for tears over 5cm)

How To Do It

1. Dry the wetsuit completely

Hang the wetsuit inside out in a warm, ventilated space for at least two hours before starting the repair. Neoprene holds moisture in its cell structure and any dampness at the repair site will prevent the adhesive forming a full bond. Do not use a tumble dryer or direct heat as both degrade neoprene. If the wetsuit was used in salt water, rinse it in fresh water first, then allow to dry.

Timing: Minimum 2 hours drying time

2. Clean both surfaces

Wipe both surfaces to be bonded with isopropyl alcohol on a clean cloth and let them dry for five minutes. The IPA removes salt residue, sunscreen, and any oils that would prevent the adhesive gripping. For a split seam, open it gently as far as it will go and clean both inner faces. You do not need sandpaper on neoprene: the material bonds without abrasion and sanding can damage the cell structure.

Timing: 5 minutes drying time after IPA clean

3. Apply the first coat to both surfaces

Spread a thin, even layer of Neoprene Queen Contact Adhesive on each of the two bonding surfaces. For a seam repair, apply to both inner faces of the open seam. For a surface tear, apply to both sides of the tear opening. The layer should be translucent and even; pooling at the edges means too much adhesive. Use a matchstick or small brush for precise application on narrow areas. Leave both coated surfaces open to the air until the first coat becomes touch dry, usually about five minutes. Neoprene Queen cures by solvent evaporation: the coat is ready when it no longer feels wet to a light touch.

Timing: About 5 minutes for first coat to become touch dry

4. Apply the second coat and wait for touch dry

Apply a second thin, even coat of Neoprene Queen to both surfaces. The two-coat method is what gives the bond its full depth: the first coat keys into the neoprene cell structure, and the second coat provides the contact layer that bonds to the opposing face. Wait again for the second coat to become touch dry before pressing the surfaces together.

Timing: About 5 minutes for second coat to become touch dry

5. Press surfaces together firmly

Align the tear or seam carefully before the surfaces make contact, because once two touch-dry contact adhesive faces touch, the bond forms instantly and repositioning is not possible without tearing the neoprene. Press firmly along the entire length of the repair with your thumbs, working from one end to the other. No clamps are needed. The instant bond formed when the surfaces are pressed together is sufficient. Leave the wetsuit flat on a hard surface.

6. Cure time: five minutes for field use, 24 hours for full strength

Neoprene Queen reaches 70% bond strength within five minutes of pressing the surfaces together. This means a repair done on the beach or poolside can be back in the water within a few minutes for light use. Full bond strength (100%) is achieved after 24 hours at room temperature. For the most demanding repairs, or where the tear is at a high-stress point such as a seam, allow the full 24 hours before returning the suit to hard use. Curing in a warm environment produces the best result; avoid curing in a cold unheated space in winter.

Timing: 70% strength in 5 minutes. Full strength in 24 hours.

Prevention Tip

Rinse your wetsuit in fresh water after every salt water session and hang it on a wide-shouldered hanger rather than a wire one. Wire hangers crease the neoprene at the shoulder and over a season that crease becomes a tear point. Store away from direct sunlight, which degrades the rubber cell structure through UV oxidation. Avoid folding the wetsuit for storage: neoprene held in a compressed fold loses cell integrity at the crease over time.

For seams showing early signs of wear, Stormsure Flexible Repair Adhesive can be painted directly over the seam on the outside of the suit and left to cure overnight. This adds a flexible, waterproof layer over any vulnerable join and is particularly useful on older suits where the factory seam adhesive is beginning to age.

Common Questions

How quickly can I get back in the water after a repair?

Neoprene Queen reaches 70% bond strength within five minutes of pressing the surfaces together, which is enough for a field repair on the beach. Clean the tear, apply the adhesive in two coats, press together, and you can be back in the water within minutes. For full waterproof strength, 24 hours is recommended, particularly for high-stress areas like seams. But the fast initial cure is one of the key advantages of Neoprene Queen over other adhesives.

Does the wetsuit need to be dry before I repair it?

Yes. The adhesive requires dry surfaces on both sides of the tear. Any moisture remaining at the repair site will prevent the adhesive forming a full bond. After a session, dry the repair area thoroughly before applying Neoprene Queen. On the beach this means towelling the area dry as well as possible and allowing a few minutes for surface moisture to evaporate before starting the repair.

Will the repair hold up to repeated use in the ocean?

A correctly applied Neoprene Queen repair is permanent and waterproof. The adhesive cures to a flexible state that moves with the neoprene through the same range of motion as the surrounding material, rather than forming a rigid point that eventually cracks away from the neoprene at the edge of the repair. A correctly prepared repair is permanent and stays flexible, moving with the neoprene through normal use.

My wetsuit has a large hole, not just a seam split. Does this change the approach?

For larger tears or where neoprene material is missing, glue a neoprene patch over the damage using Neoprene Queen. Cut a patch from spare neoprene slightly larger than the hole, apply two coats of adhesive to both the patch and the suit surface, wait for both coats to become touch dry, then press the patch firmly in place. For additional seam strength or high-wear zone reinforcement, Stormsure Flexible Repair Adhesive can be painted over the area and left to cure overnight.