Before discarding a damaged jacket, consider repair. Many common problems—small tears, stuck zippers, worn patches—can be fixed at home with basic tools and minimal skill. Repairing extends your jacket's life, saves money, and is better for the environment than replacement. This guide covers DIY fixes for the most common jacket problems.
You don't need to be a seamstress or have specialised equipment for most repairs. Basic supplies from hardware stores or online retailers handle the majority of issues. More complex repairs can be done by professionals, but you might be surprised what you can accomplish yourself.
Essential Repair Supplies
Before tackling repairs, gather these commonly needed supplies. Having them on hand means you can address problems promptly rather than letting damage worsen.
- Tenacious Tape or Gear Aid patches: Self-adhesive repair patches for quick fixes on technical fabrics
- Seam Grip or similar adhesive: Flexible, waterproof adhesive for bonding fabrics
- Needle and thread: Heavy-duty needles and thread matching your jacket colours
- Zipper lubricant: Wax-based lubricant for sticky zippers
- Iron-on patches: For fabric reinforcement and decorative repairs
- Seam sealer: For resealing taped seams that have peeled
Specialised products like Tenacious Tape are designed specifically for outdoor gear and outperform generic alternatives. The investment in quality repair supplies pays dividends in repair longevity.
Fixing Small Tears and Holes
Small tears and punctures are the most common jacket damage. Fortunately, they're also among the easiest to fix.
Using Adhesive Patches
For tears under 5cm in technical fabrics, adhesive patches provide the quickest, most effective repair. Clean the damaged area thoroughly—dirt and oils prevent adhesion. Ensure the fabric is completely dry.
Cut a patch larger than the tear by at least 1cm on all sides. Round the corners to prevent peeling. For the strongest repair, apply patches to both inside and outside of the fabric, sandwiching the tear between them.
Press firmly, especially at edges, and allow 24 hours before stressing the repair. For maximum bonding, apply gentle heat with a hair dryer before pressing—this activates the adhesive more fully.
Sewing Repairs
For tears in non-waterproof jackets where adhesive patches might look awkward, sewing provides a more aesthetic option. Use a ladder stitch (also called invisible stitch) to close tears nearly invisibly by pulling the fabric edges together from the inside.
For reinforcement, sew a patch of matching fabric behind the tear area after closing it. This prevents the stressed fabric from tearing again adjacent to your repair.
On waterproof jackets, sewing creates needle holes that compromise waterproofing. After sewing, apply seam sealer over all stitching to restore water resistance. Allow sealer to cure fully before exposing to rain.
Zipper Problems and Solutions
Zipper issues range from minor annoyances to jacket-disabling failures. Most are repairable without complete zipper replacement.
Stuck or Stiff Zippers
Zippers that catch or require excessive force often just need lubrication. Apply zipper wax or a dedicated zipper lubricant to the teeth, then work the slider up and down several times to distribute. Avoid petroleum-based lubricants, which can attract dirt and degrade fabric.
If fabric is caught in the zipper, work it free gently rather than forcing. Aggressive pulling can damage teeth or the slider. Once freed, check for frayed fabric edges that might catch again and trim if necessary.
Slider Not Closing Properly
If the zipper doesn't stay closed or separates behind the slider, the slider may be worn. Over time, sliders spread slightly and lose grip on teeth. Using pliers, gently squeeze the slider from the sides to narrow it. Work carefully—too much pressure can crack the slider.
If squeezing doesn't help, the slider needs replacement. Replacement sliders are available at fabric stores; choose one matching your zipper type (coil vs. tooth) and size. Removing and replacing sliders requires removing the top stop, sliding off the old slider, sliding on the new one, and replacing the stop.
Missing or Broken Teeth
Missing teeth on coil zippers can sometimes be repaired by realigning the coil with needle-nose pliers and securing with thread. Metal tooth zippers with missing teeth generally require complete zipper replacement—a job for professionals unless you're comfortable with sewing machines.
Zipper maintenance prevents most problems. Apply lubricant monthly during heavy use seasons, zip jackets before washing, and address minor stiffness before it becomes major failure.
Restoring Waterproofing
Waterproof jackets lose effectiveness over time as DWR (Durable Water Repellent) coating degrades and seam tape peels. Both are restorable at home.
Reapplying DWR
When water no longer beads on your jacket's outer fabric, it's time to restore DWR. First, wash the jacket according to care instructions to remove dirt that impairs treatment adhesion. With the jacket still slightly damp, apply spray-on DWR treatment evenly across all fabric surfaces.
Place the jacket in a tumble dryer on medium heat for 20 minutes to activate the treatment. Alternatively, use an iron on low heat (with a cloth between iron and jacket) to activate the DWR. Test water beading after treatment; reapply if needed.
Resealing Seams
Inspect internal seam tape periodically, especially in high-stress areas like shoulders and underarms. Peeling tape allows water ingress even if the fabric remains waterproof. Seam sealer (like Seam Grip) reseals compromised areas.
Clean the area with isopropyl alcohol to remove residue. Apply sealer in a thin, even coat overlapping onto intact tape on both sides. Allow 24 hours to cure before wearing. For large areas of tape failure, professional repair may be more effective than DIY sealing.
Down Jacket Repairs
Down jackets present unique repair challenges because of their insulation-filled construction.
Stopping Feather Loss
Small holes in down jackets allow feathers to escape continuously. Even tiny punctures need prompt repair. Apply a drop of seam sealer or flexible adhesive to seal small holes immediately—this prevents further loss while you arrange permanent repair.
For larger repairs, use iron-on patches appropriate for down jacket fabrics (typically ripstop nylon). Work carefully to avoid melting adjacent fabric. The goal is a patch that seals completely while remaining flexible.
Redistributing Clumped Down
After washing or extended compression, down can clump within baffles, leaving cold spots. While this isn't strictly "repair," it addresses a common post-washing issue. Tumble dry on low heat with tennis balls or dryer balls, which break up clumps as the jacket tumbles. This process takes longer than you expect—often 2-3 hours for complete loft restoration.
Never use high heat on down jackets. Excessive heat can damage the down clusters permanently, reducing insulation effectiveness. Patience with low-heat drying preserves performance.
Leather Jacket Repairs
Leather requires different repair approaches than technical fabrics.
Scratches and Scuffs
Surface scratches often buff out with leather conditioner applied with a soft cloth. Work in circular motions, allowing the conditioner to fill minor scratches. For deeper scratches, leather repair kits include coloured fillers that mask damage on smooth leather.
Tears in Leather
Small leather tears can be closed with leather adhesive applied to both edges, pressed together, and weighted while curing. For tears longer than 2-3cm, professional repair is recommended—leather repair requires skill to maintain appearance and structural integrity.
Worn Areas
Elbows, cuffs, and collar often show wear first. Leather colour restoration products can refresh faded areas. For significant wear, professionals can patch or reinforce from the inside.
When to Seek Professional Help
Some repairs exceed DIY capabilities. Consider professional repair for:
- Complete zipper replacement (requires sewing machine and expertise)
- Large tears or structural damage
- Extensive seam tape failure on waterproof jackets
- Significant leather repairs
- Warranty-covered damage (DIY repair may void warranty)
Many outdoor brands offer repair services for their products. Patagonia's Worn Wear, Arc'teryx's ReBird, and similar programs repair jackets at reasonable cost. Third-party outdoor gear repair specialists also provide quality service.
The cost of professional repair often compares favourably to replacement. A $50-100 repair can extend a $300 jacket's life by years—better economics than buying new, and better for the environment.
With basic supplies and willingness to learn, you can handle most common jacket repairs yourself. The skills transfer across garments, the savings accumulate, and there's genuine satisfaction in restoring gear to working condition rather than discarding it.