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Funners multi coloured waffle....

Building a sea kayak from scratch.....

Rating: 2 votes, 5.00 average.
Well, having decided to look at this kayaking m'larky but being tight and unwilling to fork out vast sums for the pleasure...
I decided to build me own boat....
this could be interesting

1st stop was finding a design I liked...I dislike some of the designs which look (to my eyes) like "Billy's 1st Kayak"
a design found, by Selway Fisher, the plans were purchased and an adventure embarked upon !

The basic premise of the design is sheets of 4mm plywood, cut to shape then stuck together using epoxy resin....
what could go wrong eh ?


Marking out the sheets for cutting


cutting the 1st of the hull shapes
at this point I'm still very unsure that it'll ever float...let alone float with me in it !
Time will tell

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  1. Funners's Avatar
    next stage after cutting out the hull shapes is to match them so they are in pairs


    the hull comprises of 4 pieces....each of those pieces is made up of three seperate pieces "stuck" together with eopxy... it'll be fine !



    epoxying the hull pieces together....the plastic sheeting is to prevent sticking it to the floor....
  2. Funners's Avatar
    Next stage after the epoxy has cured is to start wiring the hull sections together to form the shape needed......
    this is done by drilling a series of small holes in the edges of the shapes and the literally wiring them together....



    slow going and at this point not much to see for the effort......



    MMnnnn it kinda looks like a boat now..if you squint !

  3. Funners's Avatar
    The wiring together continues, sore fingers and lots of frustration really, not the easiest of tasks to wrestle with what is by now a 17 foot long reluctant piece of bendy plywood !



    eventually tho.... with the help of a temporary former...a rough kayak shape is achieved



    Updated 19-06-12 at 16:39 by Funners
  4. Funners's Avatar
    Next is the bulheads and deck formers....
    1st of all these are cut out of of ply, then shaped and finally wired into the hull to give it shape and strength



    after all the formers are wired in place, and the hull checked for true and twist the 1st of the real "sticking together" takes place.
    Making a Putty style mix of epoxy resin and filler the internal seams are caulked, this not only seals the sections but firmly sticks them together.
    once this has cured a further layer of epoxy and glass tape is applied to really bond the sections together.


    I also coat the internal ply with epoxy to strengthen and harden it.

  5. Funners's Avatar
    other timber is introduced to give the hull shape and strength, such as the inwhales which line the inner lip of the hull....





    I take the opportunity to paint out the interior that will be inaccessible after the deck is fitted



    Time taken to this point is approx 2 weeks, a lot of this is epoxy curing time, on the colder eves it would take up to 48hrs to cure sufficiently to work on the next part
  6. Funners's Avatar
    after internal painting, I continued fitting various timber sections, which were for the deck fittings later on, some of it I made up as I went along as the design didn't ask for them but on the whole things were progressing quite nicely.







    this last photo shows the cockpit formers and braces being glued into place
  7. Funners's Avatar
    Next stage was the construction and fitting of the rear decking....
    the shapes were cut out of ply as per the hull, then the centre line was stitched together as before.....
    a bead of epoxy putty was applied and then left to "jelly" at this point the deck was laid over the hull and fixed down, weight applied and then left to cure.....




  8. Funners's Avatar
    Thats all for now..... I'll be back with more pics and waffle later on
  9. Yambo's Avatar
    Excellent stuff Funners! There are lots of good designs around and I'm considering a Chesapeake Light Craft (CLC) Wood Duck for the future. First though I'll be building this, the CLC Skerry. I have the plans and some of the bits already but I don't have a workshop. I think I'll need help cutting the scarf joints as well - tests have failed so far.

    Like your kayak the Skerry is a stitch and glue construction. I'm definitely doing it this winter, even if I have to do it in my living room!
  10. Funners's Avatar
    Yambo.... TBH theres not much advantage in a scarf joint on such thin material, all of the joints in my boat are butt jointed and re-enforced either side with epoxy and tape (Selways recommendation) Slightly different if you are going for a wood finish rather than painted.
    If I can offer any advice it's pay attention to the epoxy and where it's going and what it'll look like when cured and it's a BASTARD to sand back to flat again... DAMHIK ?

    Right....a few more pics and waffle.....
    Updated 19-06-12 at 16:04 by Funners
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