Αποστολέας Θέμα: Building a sea kayak  (Αναγνώστηκε 5143 φορές)

Gardennorm

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Building a sea kayak
« στις: 27 03, 2013, 05:35:16 μμ »
Hi all,
This winter I thought it would be a good idea to have a go at building my own sea kayak.
After some internet research I found a website where I could buy plans or even the complete kit, the site is http://www.fyneboatkits.co.uk/plans/kayaks/ I chose the Night heron, stitch and Glue plans.
It says the build time is about 7 days, it took me nearly 2 months!!  :o I guess 7 days is possible if you buy the complete pack.
It was a very enjoyable build, not too complicated but it takes time to make sure all the pieces are cut correctly, then they need gluing and everything covered with polyester.
The only ply wood I could find on Skopelos was normal for indoor use, so i made extra sure it was completely covered with polyester and resin and finally a good quality polyurethane paint.
Ive used the kayak many times and in high winds and 3 meter sea to see how well it performs, I love it  ;D
Making it from plywood means it has very hard chines, this is an advantage because simply edging the kayak means I can go where ever I want without changing my paddle stroke.
It is very stable which I did not expect as the kayak is only 51 cm wide and 5.5m long, and feels really fast.
Here are the photos of the build and the finished kayak, if you have any questions just ask..  :)
The first pics are of the hull and deck being assembled.

Gardennorm

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Απ: Building a sea kayak
« Απάντηση #1 στις: 27 03, 2013, 05:38:16 μμ »
Here are the photos of the polyester being done  ;D

Gardennorm

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Απ: Building a sea kayak
« Απάντηση #2 στις: 27 03, 2013, 05:41:10 μμ »
These photos show the deck and cockpit coaming being made.

Gardennorm

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Απ: Building a sea kayak
« Απάντηση #3 στις: 27 03, 2013, 06:09:09 μμ »
These photos are of the deck and hull being joined together, this was quite difficult to make sure it was glued together properly before removing the wire stitches.
I glued as much as I could and then added polyester to the outside, when this has set i turned the kayak on its side and poured resin along the join and then added a thin strip of polyester, the smell inside the kayak was very strong!!  :o i ended up with a thin paint brush on the end of a stick to try and reach the ends of the kayak!

Gardennorm

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Απ: Building a sea kayak
« Απάντηση #4 στις: 27 03, 2013, 06:14:13 μμ »
Making the rear deck hatch took a long time because i had to cut quite a few pieces in different shapes and then clean them and glue them. But it works really well.  8)

Gardennorm

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Απ: Building a sea kayak
« Απάντηση #5 στις: 27 03, 2013, 06:17:24 μμ »
Now it was time to add the primer and paint, this took a long time because I could only add 1 coat a day and the deck had 8 coats, i then waited for 4 days for the paint to get hard before turning the boat over and adding another 8 coats to the hull!!  :o I rubbed the kayak down with 600 wet and dry between each coat of paint!  ??? a lot of work but it was worth it to get a good finish..  :D

Gardennorm

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Απ: Building a sea kayak
« Απάντηση #6 στις: 27 03, 2013, 06:25:01 μμ »
Heres the photos

Gardennorm

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Απ: Building a sea kayak
« Απάντηση #7 στις: 27 03, 2013, 06:32:09 μμ »
Now to make the seat! I researched on the internet and thought this was the best solution.
I built a bow the same width that i wanted the seat, then filled a bag with concrete, put it in the box and sat on it...  :o
This gave me a perfect mold of my bum!! i painted this to stop the dust and then covered it with cling film and then put polyester, the cling film made sure the polyester did not stick to the concrete, if it did i would end up with a very heavy kayak!!  :o

Gardennorm

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Απ: Building a sea kayak
« Απάντηση #8 στις: 27 03, 2013, 06:49:02 μμ »
final job was fitting the deck lines and then it was time to see if it floats!!!  :o
And it does!!! ;D
A lot of work but very enjoyable and the kayak is a real pleasure to paddle. If any of you are near Skopelos at any time let me know and your welcome to have a go!  :)

stelios

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Απ: Building a sea kayak
« Απάντηση #9 στις: 27 03, 2013, 08:06:29 μμ »
Great work Neil, how much it cost you the whole process?

Cheers
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Gardennorm

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Απ: Building a sea kayak
« Απάντηση #10 στις: 27 03, 2013, 08:17:06 μμ »
Hi Stelios,
The cost of the materials including the plans was about 750€, I think I can lower this cost a little with a more careful choice of suppliers!!
Cheers
Neil

thanassis

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Απ: Building a sea kayak
« Απάντηση #11 στις: 27 03, 2013, 10:28:06 μμ »
I agree with Stelios, grate job. The design, the Night Heron is fantastic. I fall in love with it when i start looking for plans to build. It is very clever the trick with the concrete.
How heavy it is?

stelios

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Απ: Building a sea kayak
« Απάντηση #12 στις: 27 03, 2013, 10:39:17 μμ »
Neil, how easy you think is to alter the design and add for example a day hatch?

Also what is the height from the hull to the thigh brace?
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thanassis

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Απ: Building a sea kayak
« Απάντηση #13 στις: 27 03, 2013, 11:26:04 μμ »
The question is addressed to Neil but I take the opportunity to answer. The modifications of this type as the day hatch is very easy, especially if you add comercial hathes. You must add third bulkhead and open up a hole.
You 're not change stractual part of the boat, instead this you add reinforcement with the bulkhead, unless you use minicell foam. This period of time i modify the foredeck of my boat to give more space to my feet. Generally the modifications are possible to these parts.
You must be more careful if you want to modify the hull or structural parts of the boat, like the bulkhead, the carlines, the stringers and so.

I must except from the above mentioned, the strip build, or pvc foam core, nomex  core boats that they achieves the stiffness of the structure by joining the hull and deck.
« Τελευταία τροποποίηση: 27 03, 2013, 11:44:56 μμ από thanassis »

Gardennorm

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Απ: Building a sea kayak
« Απάντηση #14 στις: 28 03, 2013, 08:07:50 πμ »
The height to the thigh braces is about 28cm, the cockpit area of this boat is comfortable for me and i am 1.85m tall. The cockpit being quite small makes it quite easy to connect with this boat for control and for rolling, the only thing I would say is my shoe size is a 43, if your feet are much bigger than this i think it would get uncomfortable.
Thanassis is correct, adding extra hatches would be quite easy, and although would add a little more weight would make the kayak stronger.
I did think of adding a day hatch in the fore deck as you can buy a simple kit, but instead I have added elastics to the inside of the deck above my legs, this allows for extra storage but you have to remove the spray deck to get to them.
I have learnt a lot from this build and will definitely do another next winter, many modifications can easily be done at the construction stage before fixing the deck and hull.
While researching this boat as the build was progressing there are many very good ideas for storage and fittings.