Hey everyone, I've been trying to design an ultralight float tube after I've given up on any company making one. I've tried to find a small independent ultralight backpacking company that would build one for me, but no luck there either. I've been toying with a few ideas, I was hoping I could use an existing bladder and build a cover around it, this was before I found out that the bladder is about half the float tube weight (2.98lbs for bladder, 3.89lbs for cover). So now I want to make my own bladder and cover. For the bladder I found a website saying that mylar is sometimes used for inflatable bladders, this would definitely be the lightest, but I have some concerns about durability. Do you think it would pop like a balloon if it were to be punctured? I wouldnt want to be in the middle of a lake and have my float tube blow up. PolyUrethane is a common material that is supposed to be pretty light. Can't really picture it though, I'd need a sample to figure out how light it would be. Any one have an estimate for how heavy it would be in comparison to mylar? All other aspects seem great with PU. The last material im considering is nylon (vaccuum packing material), seems pretty lightweight and strong, it doesn't puncture easily (just deforms), and it would probably bond together pretty good. The cover is where I was hoping to save the most weight, my current float tube is made out of 420 denier nylon (6.8 oz per sq yard), and 1000 denier cordura (10.8 oz per sq yard). I think those materials are overkill, I don't need my float tube to withstand a bear attack. The two dangers I see are algae covered sticks or rocks that you can kick into, and a hook catching on your tube will release or fighting a fish. The second one has me worried. I figure I just need a material that will keep the hook from hitting the bladder. I looked into cuben fiber, its light (around 1 oz per sq yard), very abrasion and puncture resistant, but I'm concerned about a hook going through and hitting the bladder. I don't really need the waterproof properties it has. Anyone know of a comparably light material that would keep a hook away from the bladder a little better? If anyone has any experience with this kind of project I would appreciate your input. I have never done any heat welding nor do I have a set up to do it. I know gluing is one method, but I don't know if Id trust it to hold air. I'm hoping to get a float tube under 3 lbs out of all of this. Currently mine weighs 7.87 lbs when its dry, that's just too much when you're trying ultralight. That, combined with waders and flippers almost triples my pack weight for a weekend trip.