Synthetic puffy pants repair

For something like that I’d use a patch as big as you can stand. Fold the edges over and stitch them to stop unraveling and glue the patch on using silicon.

Cut a piece to make a patch.  Bigger than hole.  Assuming you have a machine, sew a hem all the way around.  Then, sew that to your garment.  Sew through the patch, the fabric, and the insulation.  Sew all the way around.

You’ll end up with sewn through seam all the way around which will be colder, but not that much

Just one idea

I didn’t think about bonding the patch. Would you just do it the same as say a bonded tarp tieout reinforcement?
Do you think it would be in danger of soaking through the face fabric and ruining the apex?

Jerry, just sewing on a patch was my original idea however the hole is over halfway up the pant leg and I cannot get the pants into place on my machine to sew through just the front of the pant leg.
It seems as though I would have to cut the side open so that I could lay it flat and wanted to avoid doing that.
Not sure if that makes sense

I know what you mean, maybe try again to see if you can shoehorn it in?

If the pants are baggy you could slit it open, sew in the patch, then do a french seam to undo the slit.  Or just sew it together inside out and leave a raw fabric/apex edge inside.  The pants now a little tighter.

I don’t think sewing a seam through the fabric/apex would cause the apex damage from getting wet.  For one thing, water/sweat can go through the fabric into the apex.  Apex is very tolerant of getting wet

You could glue the patch on with seam grip around the perimeter.  Put tape on the fabric on the inside, and the outside.  It will peel off the seam grip after it dries.  Maybe put a weight over it to keep the fabric from curling.  After the seam grip dries, it will stick to itself, so rub a powdery substance on it.  For example dirt or flour.

Assuming it is entirely on the leg, I’d rip the seams open to just above and below the hole, cut the shell so there are clean edges, sew on an appropriately sized patch (you could potentially use the part you just cut out as a pattern and add seam allowance) with the seams facing the insulation (obviously), and then close the two seams you opened up originally. It may be that one of the seams is felled or double stitched, but   I kinda doubt it.

You know that feeling you get in your groin when you see a skateboarder attempt a rail slide, miss, and end up straddling the rail?  That’s what I felt when I saw that picture.

Hope your repair turns out well.

3 ideas:

1) overlapping strips of Tenacious tape

2) use a sewing machine to hem the edges of a patch, and handsew it over the knee with a whipstitch. Put a water bottle inside the pants behind the knee so you don’t accidentally sew the leg together

3) for a pro-level, better-than-new repair, send it to Santa Cruz Gear Repair or Repair Lair (if you’re in the US?). They will do the deconstruction of the leg and either match the fabric or add fun colors.

good luck!

Contact EE and ask them what is the best method of repair is for this issue  as I feel then you can proceed correctly.

that is why BPL is good, many good ideas :)

Or what about cutting a patch and affixing it with Tenacious Tape around the perimeter? Then you wouldn’t even have to hem the patch. And it’s removable if you ever want a pro repair done.

https://enlightenedequipment.com/repair-kit/

^ This is enlightened equipments suggestion, it looks like some tenacious tape type patches of a variety of sizes much larger than I have seen before. I think I’ll go with that kit because I would like to have the patches on hand anyway.