Completed Kayak

Finished at last!

Aft hatch

Rudder system in place (and partially down)

The build team

Finally get to leave the workshop (next stop the water!)

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Rudder and Sanding

Rudder or no Rudder? Opinion on rudders & kayaks appears a little divided. For me, I decided the preference was if I was going to fit one, I wanted it to be at the build stage before the kayak was finally assembled. This appeared to be the way to get the neatest job. I also decided on buying a commercially designed fitting with some 'proper' engineering. Smart Track appeared to be the one for me so it was ordered and delivered from across the Pond. Even had the pleasure of paying duty before customs would release it (which was a cost addition which I had overlooked). The fitting looks well designed and strong and folds up out of the way when not required. I purchased from this link http://www.clcboats.com/shop/products/boat-gear/kayak-footbraces-rudders/smart-track-rudder-system.html Finally a day off work coincides with dry weather and the opportunity to take the kayak outside to sand down the epoxy. All sorts of health and safety warnings I regularly ignore, but I had no intention of mixing my lungs with fine epoxy dust in a confined space!

So 'the Kayak' has temporarily lost its sparkle and shine as the epoxy gloss is lost, to be later replaced with some tough 2-pack gloss varnish.

The deck is still separate from the hull until the inside of the hull and underneath of the deck get varnished. Roll on spring and some varnishing type temperatures. This build has now been going (I think) for nine months or so, (on and off), so time to get out on the water!

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Bear Mountain Kayak

Time for another boat build!



On and off through the summer we have been working on building a 16'6" Resolute strip plank kayak from the Bear Mountain design catalogue.



'Swift' my home built sailing canoe also on this blog, was made using a completely different construction technique (lapstrake, epoxy clinker). So this strip planking in western red cedar and some yellow pine, sanded smooth and then sheathed in glass and epoxy is all new to us.





Cutting the rebate for the final outer plank is a fairly demanding job to get a good looking result. So far so good.

A scaffold frame around the kayak allows temporary timbers and wedges to hold each plank in place while the glue dries (without messing the deck up with staple holes).

The hull is finally turned over to start forming the deck around the moulds, which for now are still left within the hull.

The glass sheathing seemed to go OK and provides a hard wearing but clear finish over the timber. It will gain even more strength once the hull is glassed on the inside.

Once sanded smooth, everything needs to be clean before glassing the hull.

The planks go on, one by one around the station moulds.

The stems are laminated up in oak and held in position with the rest of the mould structure.

Each mould is cut to the exact shape and carefully set out in exactly the right position on the strongback. A mistake here will end up with a strange looking (and poor performing) kayak, so it's worth taking some time and care over this stage.

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