Building a kayak: Preparations

Considerations

Before beginning, there are a few important things to sort out.

Firstly – how much time do I have available and how long will the building take?

   (1) Type of boat & Building method

The two things need to be combined in the decision making process. Important aspects to sonsider regarding the type of boat are: intended use, the paddler’s weight and size, preferences ... The building method depends to a certain degree upon the design of the chosen boat, as well as upon one’s own abilities.

Here a few keywords:
-- Driving properties depending on the hull shape: in cross section U-shaped, V-shaped, hard chined;
in longitudinal section straight or with a rocker (‘banana-like’).
- Rudder, skeg or neither

This is followed by literature research and gathering of information, as well as the design or purchase of a construction plan ("pattern").

   (2) Where to build?

- workshed size (esp. length of the room)
- well-aired and heated (2-component products require at least 10°C for curing)
- close by, to make the most of every available minute

  (3) Tools

what is needed
what is already at hand
what can be borrowed
what has to be bought

Tools, as required for building a hybrid (hull plywood & deck strip):
Sawing – a professional circular saw with a long guide (to cut the strips), a simple slitting saw and a coping saw, perhaps a Stichsäge with a timber blade (for sawing the plywood panels)
Planing – Plane with fine-adjustment of the blade, and an exchangable blade, alternatively/additionally an electric plane with a functional mechanism to adjust the blade
Sanding- rasp and file (straight and curved), sanding paper and sanding block, Bandschleifer (to bevel the plywood and to smooth the cut panels)

For working with fibre glass and epoxy – fine scale (sticking to the exact ratio of the components is immensly important), disposable gloves, plenty of brushes, respiratory protection, glad wrap, small pots and containers (party glasses)....

Other bits ’n pieces– chisel, pocket knife, small drill, huge amount of screw clamps of all sizes, perhpas tacker - and plenty of nibbles and munchies.

  (4) Getting the material & cost calculation

Comparing prices is well worth the effort, perhaps you can get together a few boat builders and buy in bulk

The plywood I used for the hull is Okoume, water-proof glued. The sheets, 4 mm thick, are 2.50 x 1.22 m (3.05 m2).

Here I'd like to add that the use of tropical timber encourages the destruction of the unique rain forest -> link Save the Rain forest

For strip building, in general, western red zedar is used, at least in the USA & Canada, as well as by professional kit set builders (-> Literature). But I was seeking a local timber with properties similar to those of zedar (check timber properties). Though it was a difficult choice to make, I took ash, because it is very strong. It has a higher density than zedar or pine and shaping it is exhausting. On the other hand, one gets a rough-wearing boat.

At a saw mill I chose a rough hewn board in tree width to cut the strips from, for the deck.

Short overview of my incurred cost (Winter 2005/2006):

  (5) Workplan

should be set up, even thoguh it'll be changed umpteen times - useful it is nevertheless.

  (6) To practice: build an eski-paddle!

Why? It's good practice in woodworking skills and for the usage of the tools. And, the success is great for yoru confidence - Links to build a paddle.

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