If your waders fail due to a manufacturing or materials defect, Orvis will repair or replace them at our discretion, free of charge. This guarantee does not cover abuse, improper care, accidents, or the normal breakdown of materials over time. All defective or damaged waders should be returned to Orvis for evaluation, or call Orvis direct at 0870 066 4188.

Our breathable wader fabrics feature multi-layer construction “systems,” made up of three, four, or even five distinct layers. These layers, from the outermost to the innermost, for a four-layer fabric, can be described as follows:

(1) The outer shell, or “face” fabric. This is the outer most layer exposed to the environment. It needs to be durable and able to withstand puncture and abrasion. It should be supple, lightweight, and comfortable to wear,as well as flexible and lightweight enough to be easily packed and transported. This outer layer also must have a durable, water-repellent treatment on its exterior surface that causes water to bead up and roll off. The five-layer system incorporates a second layer of this face fabric for absolute puncture resistance.

(2) The face fabric is then very thinly coated on its interior surface with a microporous, breathable layer of polyurethane. This layer does two things: it helps to cover any unexpected pinholes that might develop in the main membrane, while adding overall strength to the entire system.

(3) The main membrane is next, laminated to the now-coated face fabric. This special membrane is also made of polyurethane, but it is monolithic, rather than microporous. This means that it breathes through intermolecular spaces in the membrane, rather than through microscopic holes. This provides a complete barrier to water entry, even under significant pressure, while allowing perspiration in the form of water vapor molecules to pass through to the outside. This function occurs even under water. Although held in place by the face fabric, the membrane itself is flexible and stretches enough to prevent any breakdown in stress areas, such as the seat and knees. The dry comfort that this membrane technology provides to fly fishermen, under any conditions, but especially in warm or hot weather, is revolutionary compared to the older standards of rubberized canvas or neoprene.

(4) Lastly, an innermost layer of very thin polyester tricot is pressed on the membrane with a special, breathable adhesive. This last layer protects the membrane from the inside and provides a critical surface to carry the seam-sealing tape. All seams in an Orvis breathable wader are factory-sealed with the most currently available machine technology in order to prevent any possibility of leakage. All Orvis waders are thoroughly tested at the factory for any leakage prior to shipment to our warehouse.

• Care and Cleaning
Hang, do not bundle, damp waders after use or cleaning to prevent any damaging mildew. Remove suspenders and repair kit from inside front pouch prior to washing. Store in a cool, dry place.

(1) Do not dry clean
(2) Do not use chlorine bleach
(3) Hand or machine wash, warm
(4) Air or tumble dry, low heat.

• Condensation
Even though these waders are breathable and moisture is allowed to escape, condensation may appear, particularly in the neoprene foot in both the Stockingfoot and Bootfoot models. Although much of this moisture will escape, there will be some moisture buildup in the foot, particularly when you are active. This is not due to leaks in the wader. If you do have a leak in the wader, chances are you will see significantly more water in the foot than condensation will produce.

Finding a wader leak
• The Flashlight Method
This method works for minor tears, blackberry punctures, and other small leaks. For this method you’ll need a waterproof marker and a flashlight. In a completely darkened room, place the flashlight flush with the inside of the wader in the area you suspect the leak. Identify the leak by looking for the bright spot that shows through from the outside. Pinch this spot from the outside. While holding the pinched material, turn the wader inside out and mark the polyester tricot liner as close as possible around the pinch.

• The Inflation Method
This method works especially well with Neoprenes and other fabric waders where it is not always easy to pinpoint holes using the flashlight method. You’ll need a canister-style vacuum cleaner or any type where you can reverse the hose and get the unit to blow air. You’ll also need a waterproof marker and a solution of 1⁄4 dishwashing liquid and 3⁄4 warm water in a small bucket.
   Constrict the upper of the wader around the vacuum cleaner hose and turn the vacuum on. (It helps to have two people for this procedure.) Once the waders are inflated, let enough air in to keep it inflated without overextending the wader and putting too much pressure on the seams. Carefully brush the soapy water over the area you suspect may be leaking; any leaks will show up as active bubbles as you brush the mixture on the waders. A leak will be easiest to spot if you avoid creating bubbles when brushing the mixture on the waders. Circle leaks with the waterproof marker.

• Alcohol Method
Fill a small spray bottle with rubbing alcohol. Saturate the outside of the wader around the area where you suspect the leak. Immediately turn the wader inside out. Examine the inside, polyester tricot material. A leak usually will reveal itself as a darker spot on the polyester tricot liner.

Repair instructions
• Repair kit, including tape and fabric swatches, are in the zip pocket in the pouch in the wader front.
• Turn iron to low steam polyester/viscose and turn waders inside out.
• For small tears, cut a piece of the fabric tape to size and place over the hole, white side down.
• Press with iron for 10 seconds. Rub with a cool piece of fabric to set.
• For larger tears, cut a piece of the wader fabric patch to size and place over tear, gray side up.
• Cover edges of patch with heat tape, white side down. Press with iron for 10 seconds and rub with cool fabric to set.
• Wader repairs using Aquasure®, or for large tears. Iron-on seam tape won’t work with large tears, holes in rubber boots, or holes in neoprene. But that’s no reason to retire your favourite waders! The most complete wader repair kit available on the market, containing Aquasure, is designed and sold only by Orvis. An Orvis Aquasure Repair Kit can be obtained from Orvis retail stores, or by calling 0870 066 4188. Individual, 1-ounce tubes of Aquasure are also available.

Find the leak by one of the methods listed here. Clean the area to be patched with alcohol (leaks are best patched from the inside). Apply a thin coat of Aquasure to the hole and an area about one-half inch beyond the tear. When the Aquasure is very tacky (in about five minutes), cut a piece of light polyester fabric, or polyester stocking material, to match the glued area and smooth it over the area. It helps to place some wadded newspaper on the other side of the repair to give you something to press against and to keep from gluing your wader legs together.

Back to Top of Page

Back to Previous Page