A small tear or split doesn’t necessarily mean your wetsuit needs replacing. Many common wetsuit problems can be repaired at home using Black Witch neoprene adhesive, Aquaseal SR, Stormsure, or similar flexible wetsuit repair products.
This guide covers the basic repairs you can safely tackle yourself, from small cuts and pinholes to split seams and loose neoprene.
What You’ll Need
For most basic repairs, keep a small wetsuit repair kit containing:
- Black Witch or another flexible neoprene adhesive
- A small brush or applicator
- Isopropyl alcohol or mild soapy water for cleaning
- Clean cloth
- Masking tape
- Wooden lolly stick or similar tool for spreading adhesive
- Small scissors
- Tweezers
- Heavy books or a flat weight
- Baking parchment or plastic film
- Disposable gloves
- A well-ventilated working area
Important: Always follow the manufacturer’s instructions for the particular adhesive you’re using. Products can differ in curing time and application method.
Before You Start
The most important part of a wetsuit repair is preparation.
Don’t try to repair a wetsuit while it is wet, salty or covered in sand.
1. Wash the wetsuit
Rinse the wetsuit thoroughly with fresh water to remove:
- Salt
- Sand
- Mud
- Body oils
- Sunscreen
- Other contaminants
Allow it to dry completely.
2. Find the full extent of the damage
A tiny visible split can continue underneath the surface.
Gently flex the area and inspect it from both sides.
Look particularly carefully around:
- Seams
- Armpits
- Crotch
- Knees
- Ankles
- Wrists
- Neck
- Zip ends
3. Clean the repair area
The adhesive needs a clean, dry surface.
Use mild soapy water first and allow the neoprene to dry completely. If the adhesive manufacturer’s instructions permit it, a small amount of suitable solvent such as isopropyl alcohol can be used to remove grease.
Don’t soak the neoprene in solvents or use aggressive chemicals.
Repairing a Small Cut or Tear
This is one of the easiest wetsuit repairs.
Step 1 – Open the cut slightly
Gently separate the edges of the cut so you can see where the adhesive needs to go.
Don’t stretch the neoprene excessively.
Step 2 – Apply Black Witch
Apply a thin layer of adhesive along the damaged edges.
You don’t need to flood the hole with glue.
A thin, controlled layer normally produces a much neater and more flexible repair.
Step 3 – Allow it to become tacky if required
Some neoprene adhesives work best when allowed to become tacky before the surfaces are joined.
Follow the instructions on your particular product.
Step 4 – Bring the edges together
Carefully align the two sides of the tear.
Try to keep the neoprene in its natural position rather than stretching it.
Step 5 – Hold it in place
Use masking tape or a suitable weight to keep the repair closed while it cures.
Avoid sticking ordinary adhesive tape directly over uncured Black Witch if it could interfere with the adhesive.
Step 6 – Allow it to cure
Leave the repair undisturbed for the recommended curing period.
Don’t put the wetsuit straight back into the sea just because the adhesive feels dry on the surface.
Repairing a Split Seam
Split seams are extremely common, particularly on older wetsuits.
You may notice water entering through a seam or see the stitching/taped seam beginning to separate.
Small seam split
For a small section of separated seam:
- Clean and completely dry the area.
- Carefully open the split enough to access the inside.
- Apply a thin layer of neoprene adhesive to the mating surfaces.
- Allow it to become tacky if required.
- Carefully bring the seam back together.
- Hold it firmly in position.
- Allow it to cure completely.
The key is alignment. Don’t allow the seam to cure twisted or stretched.
Repairing a Larger Tear
For a larger tear, simply filling the hole with adhesive isn’t always the best solution.
A better repair can involve a neoprene patch.
Cut a piece of similar-thickness neoprene slightly larger than the damaged area.
Round the corners of the patch rather than leaving sharp square corners. Rounded corners are less likely to catch and peel.
Patch method
- Clean the damaged area.
- Cut the patch to size.
- Round the corners.
- Apply adhesive to the patch and/or repair surface according to the product instructions.
- Position the patch carefully.
- Press it firmly onto the neoprene.
- Keep it flat while curing.
- Allow it to cure fully before use.
For a heavily stressed area, consider reinforcing the repair from the inside as well as the outside.
Pinholes and Small Leaks
Tiny holes can be difficult to see.
One way to find them is to inspect the wetsuit carefully under good lighting.
You can also gently inflate or stretch a section and look for the damaged area, but don’t excessively pressurise the wetsuit.
Once you’ve found the hole:
- Clean the area.
- Dry it completely.
- Apply a very small amount of flexible wetsuit adhesive.
- Work it into the hole.
- Smooth the surface.
- Allow it to cure completely.
Don’t create a large lump of adhesive. The repair needs to remain flexible.
Using Black Witch Neatly
Black Witch is useful because it remains flexible rather than becoming a hard, brittle plug.
However, more adhesive doesn’t mean a better repair.
A common mistake is applying far too much.
For a better-looking repair:
- Use thin layers.
- Keep adhesive off undamaged neoprene where possible.
- Use masking tape to define the repair area.
- Smooth the adhesive before it cures.
- Don’t stretch the wetsuit while the adhesive is curing.
- Give it plenty of curing time.
A neat repair is generally less likely to catch on equipment or clothing.
Inside or Outside Repair?
For many tears, repairing both sides can produce a stronger result.
For example:
Outside:
Neat flexible adhesive sealing the visible tear.
Inside:
A thin layer of adhesive or neoprene reinforcement helping prevent the tear from opening again.
However, don’t blindly glue every repair on both sides. On a seam or highly flexible panel, excessive adhesive can make the area stiff.
The aim is to reinforce the damaged area while retaining the flexibility of the wetsuit.
Repairing a Wetsuit Zip Problem
Wetsuit zips need a little more care.
If the zip itself is damaged, don’t try to glue the teeth together.
First determine whether the problem is:
- Salt or sand contamination
- A stuck slider
- Damaged teeth
- Broken stitching
- A damaged zip pull
- Neoprene caught in the slider
- Separation of the zip from the wetsuit
If salt has made the zip sticky
Don’t immediately force it.
Rinse the zip thoroughly with fresh water.
If salt crystals have built up, warm—not boiling—water can help dissolve the salt.
Pour or gently flush warm fresh water over the affected area and work the zip slowly.
Never use boiling water.
Once clean, allow the area to dry and use a suitable wetsuit/zip lubricant if recommended by the manufacturer.
If the zip teeth or slider are physically damaged, adhesive is unlikely to be a proper repair. A specialist wetsuit repairer may be needed.
Repairing Neoprene Around the Zip
A common failure is the neoprene next to the zip beginning to split.
This can often be repaired using flexible neoprene adhesive if the zip itself is still working correctly.
Clean the area thoroughly and repair the neoprene in stages rather than trying to glue a large damaged section in one go.
Make sure the zip remains completely free of adhesive.
Never glue the zip slider or teeth.
Loose Seam Tape
Some wetsuits use internal seam tape to reinforce glued and stitched seams.
If a small section begins to lift, it may be possible to reattach it using an adhesive recommended for wetsuit seam repair.
Don’t simply cover a large section with glue without first finding out why the tape has lifted.
If the seam is extensively failing, professional repair is usually the better option.
When NOT to DIY
Basic repairs are great for small damage, but some problems are better left to a professional wetsuit repairer.
Consider professional repair when you have:
- A large tear
- Extensive seam failure
- A damaged zip
- A completely detached zip
- Major damage around the neck
- Large holes in high-stress areas
- Extensive deterioration of the neoprene
- Multiple repairs throughout an old wetsuit
- Crumbling or hardened neoprene
If the neoprene itself has become brittle, cracked or badly compressed, repairing one hole may simply reveal the next problem.
At that point, replacing the wetsuit may make more sense.
Common Repair Mistakes
❌ Repairing wet neoprene
Adhesive won’t bond properly to a wet, salty surface.
Do this instead: clean and completely dry the area first.
❌ Using superglue
Superglue becomes hard and brittle.
Wetsuits constantly flex and stretch, so a rigid adhesive can crack and fail.
Use a flexible neoprene adhesive instead.
❌ Applying too much Black Witch
A huge blob of adhesive isn’t necessarily stronger.
It can make the repair stiff and uncomfortable.
Use controlled, thin layers.
❌ Pulling the tear together too aggressively
Stretching the neoprene while repairing it can leave the area under tension.
When you put the wetsuit on, the repair can then fail.
Repair the wetsuit in its natural relaxed position.
❌ Getting adhesive on the zip
Glue on a zip can cause even more problems.
Keep the slider and teeth completely clean.
❌ Using the wetsuit too soon
A repair that feels dry isn’t necessarily fully cured.
Give the adhesive the full recommended curing time.
A Simple Emergency Surf Repair
If you’re at the beach and discover a small tear, you may be tempted to repair it immediately.
For a proper repair, however, it’s much better to:
- Rinse the wetsuit with fresh water.
- Let the damaged area dry.
- Clean the area properly.
- Apply the appropriate adhesive.
- Allow it to cure fully.
- Inspect the repair before returning to the water.
If you’re already at the beach and don’t have the correct repair materials, don’t make a permanent repair with whatever glue happens to be in the garage.
A temporary solution is preferable to damaging the neoprene further.
Building a Wetsuit Repair Kit
A small repair kit is worth keeping in your surf bag or van.
Basic kit
- Black Witch or equivalent neoprene adhesive
- Small scissors
- Tweezers
- Masking tape
- Clean cloth
- Small piece of spare neoprene
- Disposable gloves
- Small plastic bag/container for keeping everything together
For regular surfers, carrying a small repair kit can save a wetsuit from becoming unusable because of a simple tear.
Black Witch Alternatives
Black Witch isn’t the only product suitable for wetsuit repairs.
Other flexible repair products include:
- Aquaseal SR
- Stormsure
- Other purpose-made neoprene/wetsuit adhesives
- Neoprene cement designed specifically for wetsuit repairs
Check that the product is suitable for neoprene and flexible applications.
Avoid general-purpose household adhesives unless the manufacturer specifically states that they are suitable for neoprene and repeated flexing.
Looking After Your Wetsuit Prevents Repairs
The best repair is the one you never need to make.
After surfing:
Rinse
Give the wetsuit a thorough freshwater rinse.
Dry correctly
Dry it away from direct, intense sunlight and excessive heat.
Don’t hang it from the neck
A heavy wet wetsuit hanging from the neck can put unnecessary stress on the neoprene.
For long-term storage, avoid leaving it tightly folded.
Take care when putting it on
Use the pads of your fingers rather than your fingernails.
Sharp fingernails are one of the easiest ways to create small punctures and tears.
Don’t pull aggressively
If the wetsuit feels tight, don’t simply pull harder.
Work the neoprene gradually into position.
Final Advice
A good wetsuit can often be kept going for years with a little care and the occasional repair.
Black Witch and similar flexible neoprene adhesives are excellent for small cuts, pinholes and minor seam damage, but they’re not a magic solution for every wetsuit problem.
The golden rules are:
Clean it → dry it → prepare it properly → use a thin layer → keep it aligned → let it cure fully.
If the damage involves a zip, a large section of seam, or badly deteriorated neoprene, it’s usually worth getting professional advice rather than repeatedly repairing it yourself.
For surfers in Yorkshire, keeping a small wetsuit repair kit in your car or surf bag is particularly useful. A small tear discovered before a session can otherwise turn into a much bigger problem when you’re pulling the wetsuit on.
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