If you have horses, you have torn sheets. It is an unavoidable truth of horse ownership. One minute your horse is peacefully grazing in their brand new clothes and the next they have caught it on a fence, played too rough with a pasture mate, or simply decided that today is the day to test the durability of your investment.

The good news? Most horse clothing damage is repairable. With the right techniques and materials, you can extend the life of your protection gear significantly. Replacements can cost $80 to $200 or more, while a proper repair might cost you $5 in materials and an hour of your time.

This guide covers everything you need to know about how to repair horse sheets and blankets. We will walk through assessment, materials, step-by-step repair methods, and when to admit defeat and buy new.

What You Will Need for Repairs

Before you start any repair, gather your materials. Having everything on hand prevents the frustration of stopping mid-project to hunt for supplies.

Essential Materials

• Dental floss (thick, unwaxed) - This is the secret weapon horse owners swear by. Regular thread breaks. Dental floss does not.

• Upholstery thread and heavy-duty needle - For machine sewing or hand-sewing larger repairs

• Fabric patches - Polar fleece, heavyweight lycra, or scraps from old fly sheets work best

• Fray Stop or similar sealant - Prevents raw edges from unraveling further

• Stormsure adhesive or tent seam sealer - For waterproofing and reinforcing patch edges

• Schneider's Horse Blanket Repair Tape - For quick fixes on turnout blankets (note: not ideal for fly sheets)

• Iron-on patches - Quick reinforcement option

• Alcohol swabs - For cleaning synthetic fabrics before adhesive application

Tools

• Sewing machine (optional but helpful for straight tears)

• Hairdryer (for heat-activated patches)

• Sharp scissors

• Ruler or measuring tape

The quality of your materials matters. Cheap thread will break. Cheap adhesive will peel. Since you are trying to save money by repairing rather than replacing, invest in decent supplies.

Assessing the Damage: Repair or Replace?

Not every tear deserves your time. Here is how to decide whether to repair or retire a piece.

When to Repair

• Small tears (under 6 inches) - These are definite repair candidates

• Medium tears (6-12 inches) - Repairable with proper reinforcement

• Clean rips with minimal fraying - Easier to mend than shredded areas

• Damage to non-stress areas - Tears on flat panels repair better than those at seams or straps

When to Replace

• Multiple large tears - If the sheet looks like it lost a fight with a lawnmower, retire it

• Damage to straps, buckles, or hardware - These require professional repair or replacement

• Extensive degradation - When the fabric itself is breaking down, patches will not help

• Cheap sheets - Sometimes a $40 sheet is not worth a $20 repair kit and two hours of labor

Here is a practical truth: quality sheets and blankets are worth repairing. A well-made one can last for years with proper care and occasional repairs. Cheap pieces often are not worth the effort.

The Repair Decision Framework

Consider these factors:

• Age and overall condition - A two-year-old sheet with one tear? Repair it. A five-year-old sheet with fading, stretched elastic, and multiple weak spots? Replace it.

• Original quality - Higher-end with quality construction merit more repair effort

• Location of damage - A tear on the shoulder (high movement area) needs stronger repair than one on the back

• Your skill level - Be honest about whether you can execute a repair that will hold

Method 1: Sewing Tears With Dental Floss

This is the repair method horse owners consistently recommend across forums and communities. There is a reason for that: it works.

Why Dental Floss Works

Dental floss is stronger than any thread you will find at the fabric store. It was designed to withstand friction and tension between teeth. On a horse blanket, it holds up to rolling, rubbing, and washing far better than standard thread.

As one experienced horse owner noted: "Dental floss is the key. It is the BEST, strongest thing to repair tears with." Another added: "If it is good enough for ballerinas' shoes, it is good enough for the horses."

Step-by-Step Instructions

Step 1: Prepare the area Clean the torn area thoroughly. Dirt and oils prevent proper adhesion if you are adding patches later. Let it dry completely.

Step 2: Stop the fraying Apply Fray Stop or a similar fabric sealant to all raw edges of the tear. This prevents further unraveling while you work. Let it dry according to product instructions (usually 15-30 minutes).

Step 3: Position the tear Butt the edges together. Do not overlap them. Overlapping creates a ridge that can rub your horse and creates a stress point where the repair will fail.

Step 4: Thread your needle Use thick, unwaxed dental floss. Waxed floss can be slippery and may not hold knots as well. Double the floss for extra strength, tying the ends together.

Step 5: Sew the tear closed Use a whip stitch or zigzag pattern. A whip stitch wraps around the edge of the fabric. A zigzag goes back and forth across the tear. Both work. Choose the one you can execute most neatly.

Step 6: Reinforce beyond the tear Do not stop sewing at the end of the tear. Continue your stitches 1-2 inches into the undamaged fabric on both sides. This distributes stress and prevents the tear from reopening.

Step 7: Secure the ends Tie off with several knots. Dental floss can be slippery, so use extra knots and a drop of Fray Stop on the knot if desired.

Pro Tips for Dental Floss Repairs

• Test your stitch tension on a scrap first. Too tight and you will pucker the fabric. Too loose and the repair gaps.

• For extra strength, sew a second line of stitches perpendicular to the first, creating a cross pattern over the tear.

• If hand-sewing is difficult, use a thimble. Pushing a needle through multiple layers of mesh and patch material takes pressure.

Method 2: Patching Holes

When there is actual fabric loss (a hole rather than a tear), you need to add material rather than just closing a gap.

Best Patch Materials

• Polar fleece - Does not fray, stretches slightly, and is soft against the horse's skin

• Heavyweight spandex - Durable, stretchy, and conforms well to the sheet's shape

• Scraps from old fly sheets - Matches the material properties exactly

• Old bedsheets or pillowcases - Budget option that works in a pinch

One horse owner recommends: "I try to have some light-weight polar fleece on hand for repairing sheets. Fleece does not fray, is a bit stretchy, and is soft against their skin."

Step-by-Step Patching

Step 1: Clean and prepare Clean the damaged area and let it dry. Apply Fray Stop to any raw edges of the original tear.

Step 2: Cut your patch Cut a piece of patch material 2-3 inches larger than the hole on all sides. This gives you adequate area to attach the patch without the edges pulling loose.

Step 3: Prepare the patch edges Apply Fray Stop to the edges of your patch material (unless using fleece, which does not fray). Let it dry.

Step 4: Position the patch Place the patch on the UNDERSIDE of the sheet. This hides the repair from view and protects the patch from direct sun and weather.

Step 5: Attach the patch Using dental floss or upholstery thread, sew around the entire perimeter of the patch. Use small, tight stitches. A whip stitch or blanket stitch works well.

Step 6: Optional sandwich reinforcement For high-stress areas or larger holes, add a second patch on top of the sheet (outside), creating a "sandwich" with the fly sheet fabric in the middle. This doubles the strength.

Step 7: Seal the edges Apply Stormsure adhesive or tent seam sealer around the edges of the patch. This waterproofs the repair and prevents the edges from peeling.

Method 3: Using Repair Tapes and Adhesives

Sometimes sewing is not practical. Maybe you do not have time. Maybe the tear is in an awkward spot. Maybe you simply do not sew. Adhesive options can work, with caveats.

Schneider's Horse Blanket Repair Tape

Schneider's Horse Blanket Repair Tape is a pressure-sensitive, self-sticking tape made from waterproof ripstop nylon. It costs $5.99 to $8.99 per strip (approximately 3 inches by 18 inches).

The catch: According to Schneider's customer service, this tape "will not work as well on fly sheet material." It is designed for turnout blankets and stable sheets. For fly sheets, they recommend sewing with fishing line instead.

If you do use it on appropriate materials:

• Clean the area thoroughly first

• Apply pressure firmly

• For extra hold, iron on warm (not hot) setting

• Not recommended for fleece

Tear-Aid Patches

Tear-Aid makes repair patches specifically designed for fabric and vinyl. Their Type A patch works on most fabrics including nylon, polyester, and canvas.

Key features:

• See-through patch works with any color

• Peel-and-stick application (no sewing)

• UV resistant and holds up under pressure

• Cuts to any size with scissors

• Starts at $8.99 for retail kits

For mesh fly sheets, Tear-Aid can be effective because it does not require sewing that could further compromise the mesh structure.

NoSo Patches

NoSo Patches are heat-activated adhesive patches designed for outdoor gear. They apply like a sticker, then you activate the adhesive with a hairdryer.

Pricing ranges from $9.99 to $15.99 for individual patches. They are machine washable after application and come in decorative designs if you want to turn your repair into a statement.

The company emphasizes sustainability, having helped save over 3 million pieces of outdoor gear from landfills.

Stormsure Adhesive

Stormsure makes flexible repair adhesives that cure to a waterproof, flexible finish. Their products range from $6 to $12 and are particularly useful for:

• Sealing the edges of sewn patches

• Waterproofing repairs on turnout sheets

• Patching small holes without fabric patches (using TUFF Tape)

Their TUFF Tape self-adhesive patches ($6 to $9 per pack) provide instant patches that can be applied without waiting for adhesive to cure.

Textilene-Specific Repair Considerations

If you own Kensington fly sheets, you are working with Textilene fabric. This woven PVC-coated polyester mesh has unique properties that affect repair approaches.

Textilene is engineered for:

• 73% UV protection

• 78% air permeability

• Resistance to fading, mildew, and extreme weather

Repair Implications

Standard sewing can compromise Textilene's woven structure. The fabric is designed as a mesh, and every needle hole potentially weakens the overall integrity.

Best practices for Textilene repairs:

• Use mesh-specific repair patches like Tear-Aid Type A

• Minimize needle holes by using longer stitches

• Consider professional repair for extensive damage

• Reinforce repairs with adhesive on both sides

The goal is preserving the UV protection and breathability that make Textilene valuable. A sloppy repair that blocks airflow or creates weak points defeats the purpose of investing in quality fabric.

Learn more about why Textilene fabric matters for your horse's protection.

When to Seek Professional Help

DIY repairs have limits. Know when to call in the pros.

Beyond DIY Skills

• Buckle and strap replacement - Requires hardware installation that most home sewers cannot execute properly

• Extensive damage across multiple panels - Professional repair services have industrial machines that handle heavy repairs better than home equipment

• Expensive sheets under warranty - Check if your repair voids any lifetime guarantee coverage

What Professional Repair Costs

Professional blanket repair typically runs $20 to $50 per repair, depending on damage extent and your location. Services usually include:

• Industrial machine sewing

• Proper hardware replacement

• Matching materials when possible

• Waterproofing treatments

Finding a Repair Service

Check with:

• Local tack shops (many offer repair services or know who does)

• Dry cleaners (some handle blanket repairs)

• Mail-in services (search "horse blanket repair" online)

• Local seamstresses experienced with heavy fabrics

Preventing Future Damage

The best repair is the one you do not have to make.

Fit Matters

A properly fitted fly sheet resists tearing better than one that is too tight or too loose. Sheets that shift create rub points and catch hazards. Take time to measure your horse correctly and choose the right size.

Environmental Checks

Walk your turnout areas regularly:

• Remove or pad sharp fence edges

• Check for protruding nails, screws, or wire

• Trim branches at horse height

• Separate horses that play too rough

Regular Maintenance

Catching small tears before they grow saves significant money:

• Inspect sheets weekly during fly season

• Repair small tears immediately (they grow exponentially)

• Clean sheets before storage (dirt and sweat degrade fabric)

• Store properly in a dry area

For a complete maintenance guide, see how to inspect and maintain your horse blankets and fly sheets.

Keep Your Horse Protected With Quality Gear

Fly sheet repair is a practical skill that saves money and reduces waste. With dental floss, some basic materials, and a little patience, you can extend the life of your horse's protective gear significantly.

But know when to let go. A sheet held together by prayers and duct tape is not protecting your horse. Sometimes replacement is the smarter choice, especially when you can invest in quality gear built to last.

Kensington Protective Products has been shielding what matters most since 1954. Our protective fly sheets and winter blankets are built durably, backed by a lifetime guarantee, and designed to withstand the realities of horse life. When you invest in quality, repairs become maintenance rather than emergency triage.

Because at the end of the day, your horse does not care about the brand. They care about being comfortable, protected from flies, and free to be their magnificent, occasionally destructive selves.

Frequently Asked Questions

Can you explain how to repair horse sheet tears that are longer than 12 inches?

For tears longer than 12 inches, use a patch backing rather than just sewing the edges together. Cut a fabric patch (polar fleece works well) 3-4 inches larger than the tear on all sides. Sew the patch to the underside of the fly sheet using dental floss, creating a reinforced panel. Then sew the tear edges together through the patch material. This distributes stress across a larger area and prevents the tear from reopening.

What is the best thread to use when learning how to repair horse sheet damage?

Dental floss is the most recommended material for repairing fly sheets. It is stronger than any sewing thread, holds up to washing, and resists the abrasion that comes with horse wear. Use thick, unwaxed dental floss and a heavy-duty needle. Many experienced horse owners say they have tried various threads, but dental floss consistently outperforms them all.

Is duct tape an acceptable method for how to repair horse sheet tears quickly?

Duct tape works as a temporary emergency fix, but it has significant limitations. It often fails in humidity and heat, leaves sticky residue that attracts dirt, and can actually damage fabric when removed. If you must use duct tape, apply it to both sides of the tear so the adhesive surfaces stick to each other through the mesh. Remove it as soon as possible and perform a proper repair.

How do I know if my sheet is worth repairing or if I should replace it?

Consider repair for quality sheets with isolated damage under 12 inches, sheets less than 3 years old, and tears in non-stress areas. Consider replacement for cheap sheets (under $50), multiple large tears, extensive mesh degradation, or damage to straps and hardware. A good rule: if repairs would cost more than half the price of a new sheet, replace it.

Can I use regular iron-on patches for how to repair horse sheet holes?

Standard iron-on patches can work for small holes in synthetic fly sheets, but they often peel over time due to the flexible nature of the fabric and outdoor exposure. For better results, sew around the edges of the iron-on patch with dental floss after applying it. This mechanical attachment prevents peeling while the adhesive provides initial hold.

What should I do if my horse keeps tearing the same spot on their sheet?

Repeated tearing in the same location indicates either a fit issue or an environmental hazard. Check that the sheet fits properly (not too tight or loose). Inspect the turnout area for the specific hazard causing the damage (fence edges, gate latches, protruding objects). Consider adding a reinforcement patch to that area even before damage occurs, or look for a sheet design with reinforcement in high-wear areas.