I was getting flats on every single ride even rollers. I found it was where an object went thru the tire and there was a tiny 1/8 inch cut in the tire. There was nothing in the cut but for some reason I would get a small hole in the tube there. I used a Rema patch on the inside of the tire as a boot. Now for some reason it is flatting right where the boot is attached to the inside of the tire. Perhaps the tube is binding against the patch causing a hole to develop due to uneven expansion rate.

I just now put a bunch of baby powder between the tire and tube in hopes of allowing less friction between the tire and tube. The tire is a GP4000s II and it is only a few months old. I am debating about trying to remove the boot and see if I can put some super glue in the crack or some shoe goop. Any other ideas what I can do to combat this issue? I also wonder if I ran only 110lbs instead of 120lbs would it help the issue. I weight 240lbs but I think I might be able to get away with 110lbs since I very rarely hit rocks or pot holes.

Try using something more substantial as a boot.

+1
I've had some luck using a 3 - 4" section of old inner tube inside the tire, covering the hole. I would not use superglue on any hole that goes through the tire cord casing.

A couple of layers of duct tape should be enough to cover the hole.

I like the idea of using an old inner tube as a boot. I guess I could use some tape to hold it in place. Now I hope I can get the Rema patch off the inside of the tire. I made sure it was stuck real good.

Leave the patch on...Cover it with 2 layers of duct tape.

Or cut a small piece of these.

NB: you can buy a new tire as easily as complain, on the internet.

Cut a flap from a Federal Express-style Tyvek mailing envelope into tire-boot-sized pieces. Peel and stick inside the tire. I always use two pieces, for insurance. Not a bad idea to carry several of the adhesive Tyvek patches on rides.

A tire boot isn't supposed to stretch, and that is just what a piece of inner tube will do. Any building sites near you? Tyvek is a product used as a vapour barrier in new homes. It just so happens to be an ideal material for a tire boot. It is thin, very strong and will not stretch. Far better than a patch or a piece of inner tube

more substantial boot material, and less PSI will approach the solution to the problem from both ends.

I've had this happen twice in 30 years of riding. What happens is the hole is big enough to let the tube push through but not enough to let it pop. As you're rolling, the tube wears where it contacts the road.

As others point out, a substantial tire boot is required to keep the tube contained. A regular tire patch stretches too much. The only permanent solution is a new tire.

IMO, this is counterproductive. If the tube and tire surfaces are clean, they'll stick to each other and with no relative movement, the tube can't wear. If the tube can move with respect to the the tire, it will wear.

Thanks for the feedback folks. This morning was my first ride (55miles) in the last 8-10 where I didn't get a flat. Maybe the 110psi and baby powder helped or I just got lucky. Either way I will be looking for some Tyvek to use as a temporary boot. Will the Tyvek work OK without removing the patch. Long-term I will be looking for the GP 4000s II to go on sale. I would like to replace the tire right away but, I can't afford the $70+tax the LBS sells them for.

Gluing down dacron sailcloth with contractor grade contact cement makes for permanent patches that last the life of the tire. I do regular repairs on Vittoria Open Paves which are a very good rolling and very grippy tire in the wet, but pick up road debris very easily (the downside of the great grip). At $70/tire, extending their life with boots by hundreds of miles is, for me, a no-brainer.

Ben