It is Sheri chiming in on this one. Yes, we have had occasional leaks show up on the 03 and 04 models under the floor. If your boat has yellow tape it is either an 03 or an 04 model. Those are the only two years with the yellow tape. That issue did resolve itself with the black tape. The cause takes way too long to explain, and it was one of those things you don’t find until a couple of years down the road.
Fortunately there is a very good fix for this problem. We are happy to do it for you or you can tackle it yourself. The hardest part of doing it yourself is first getting a hold of some Clifton one part adhesive or Stabond adhesive. These are both contact glues for urethane. These two glues are my first choice to do the finishing of the repair. You can make patch n go work just fine, but for a permanent repair of the size you will end up making I prefer to go ahead and put a fabric patch on. The next hard part, and this seems to gag everyone, is you have to cut into your boat. it is like stabbing your dog for most people. But fear not, it repairs easily and it is the only way to get to the root of the leak problem.
First find exactly where your leak is coming from and mark the tube above this spot.
Next make a vertical cut in the tube above this leak. I usually go for the inside of the tube so it isn’t so visible. The cut should be about 4 inches long. Don’t too near the floor either, it will make it more difficult to close this hole properly.
Now that you have the inside of the tube exposed match up where you marked the leak on the outside with what you see on the inside. Wipe this area with alcohol and put a good sized bunch of aquaseal over it. Let the aquaseal cover at least two inches more than what you are seeing as the leak area. You are covering the actual main seam here.
Let the aquaseal dry overnight.
The next day take patch n go and close off the inside edge of the cut in the tube. Take a look at my repair video on the site to see how to do this step.
Then you can put patch n go over the outside of the cut or you can get a scrap of fabric from us and use the contact adhesive that I mentioned earlier to apply a patch. With both the patch n go and the fabric patch make sure your patch is at least 1 1/2 inches wider than the cut line on all sides.
You cannot repair this problem from the outside. The air will just leak around your sealing attempt. You must get to the inside of the tube. But, if you do swallow hard and rip into the boat and repair it from the inside the boat will be 100% again.
Or you can just send it down and we will fix it for you. Also, if you guys are in Anchorage I can give Eric Parsons a good tutorial on how to fix it and you can give him a shout. He does really good repair work.