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Glad to hear that Avon has a road hazard program, that worked out pretty well for you.
On the subject of using a tire after you have driven on it flat: First, it's not something that is recommended, and there are good reasons for it. When you drive on a flat tire, you're pinching the sidewall/face of the tire between the rim and the road in a way that it was not designed to be. The cords that run in your sidewall are nylon, the steel belts that we all hear so much about are only found in the face, or tread, of the tire. As you ride on a flat, you will start to break some of these cords, which can cause a ply separation, which can lead to a blow out, which can lead to you maybe dying.
If you are really wanting to re-use the tire that you rode flat on, you need to give it a thorough inspection. This means that the tire must come completely off of the rim, and you must look at the inside of the tire. If you pull the tire off, and there is a bunch of rubber (almost looks like confetti) laying inside the tire, it's junk. Throw it out. If there's no rubber confetti, inspect the sidewall, if there's a ring of discoloration, there may be internal damage, and it's at your discretion that you continue to run it. Just remember, if you're in doubt, is it worth the $200+ for a new tire if the benefit is it reduces the chances of your life coming to an abrupt end?
If everything looks ok, and you need to repair the hole that caused the flat, remember the following: A plug is a temporary solution. If you have a tubed tire, then the plug can be a long term solution, but if your tire is tubeless, you need to get an internal patch. A plug may be sealed on the outside, and not allow air to escape the tire, but it can allow air to leak into the part of the tire that holds the cords, which can lead to a ply separation, then a blowout, and then you maybe dying.
In the end, it all comes down to how much value you place on your life.
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