How to Repair Hiking Trousers – Tears, Knees and Seams

Where hiking trousers fail – and why

Hiking trousers wear at predictable spots. The knees take the hit when you kneel or scramble, the seat wears against rock and ground, and the inner thighs and crotch seam rub against each other until the fabric finally gives (an abrasion blowout, not a clean tear). Lower down, the hems wear from boot heels and scree, and belt loops and zips are their own weak points. The material decides how you repair: softshell is a woven stretch fabric, thin hiking trousers are often nylon or ripstop, and many have reinforced panels of heavy fabric (such as Cordura) at the knee and seat. Ripstop has reinforcing threads woven in a grid that slow a tear – but once one takes hold, it has to be stopped with a patch.

Choose the right repair for the damage

The method depends on the type of damage:

• Small tear or abrasion hole in thin fabric or ripstop: a self-adhesive repair patch on the inside – and ideally one on the outside too. Round the corners so they don't lift.
• Worn knee or seat: a reinforcing patch of similar fabric sewn on from behind, then topstitched on the outside.
• Split crotch seam: restitch the seam and reinforce with a patch behind it – this is the most stressed point on the trousers.
• Frayed hem or cuff: rehem and reinforce with a bar tack where wear is greatest.
• Loose belt loop or a zip that has failed: separate, self-contained repairs – see the related articles.

How to patch a tear or a worn knee

A well-anchored patch can give hiking trousers many new seasons. Work on a clean, flat surface and let any glue cure as the maker specifies.

1. Clean and dry the area well – patches and glue won't bond to dirt or moisture.
2. Trim loose threads around the tear, but no more fabric than necessary.
3. Cut a patch generously larger than the damage on every edge, and round the corners so they don't catch and lift in use.
4. For a small tear in ripstop or thin fabric: apply a self-adhesive repair patch on the inside, optionally one on the outside too, and press firmly until the glue grips.
5. For a worn knee or seat: place a reinforcing patch of similar fabric behind the hole, and sew it on with dense stitches all around the edge – two passes in the most exposed zones.
6. If the trousers are softshell or stretch, sew with a stretch or zigzag stitch so the seam follows the fabric without breaking.
7. Trim the threads and check the edges lie flat against the fabric.

Don't weaken the water repellency when you repair

Many hiking trousers have a durable water-repellent (DWR) surface or reinforced, laminated panels. Avoid ironing directly on such fabric – too much heat can damage the membrane or laminate. Use repair patches made for technical gear, and let the glue cure as the maker specifies rather than forcing it with heat. Once the repair is set, it is worth testing the water repellency on the repaired area: sprinkle a few drops of water on the spot. If the water beads and rolls off, you are done. If it soaks in and darkens the fabric, the trousers may need re-proofing – a separate job from the patching itself.

Send your hiking trousers to us

If the trousers are softshell, have reinforced or laminated panels, the damage is large, or you want to be sure the repair doesn't compromise the water repellency? Then you can send the trousers to us. We repair tears, worn knees and seats and split seams on technical outdoor gear, according to the garment and its fabric, and can handle a zip or belt loop in the same round. You order online anywhere in Norway, and you see the price before you order.

Frequently asked questions