Description
This article is from the Sea
Kayaking FAQ, by Todd Leigh with numerous contributions by
others.
18 How do I build a kayak?
Author: Nick Schade
Strip-built (SB) and Stitch & Glue (S&G) are two methods of
home-building a kayak. There are also several methods of constructing
"traditional" skin covered kayaks, some other techniques for plywood,
and you can also use a mold. One method of building skin and frame
boats is described here. Other methods may be added to the FAQ at a
later date.
Strip Built Vs. Stitch & Glue: The two building processes SB and S&G
are quite different. In SB you bend narrow strips around a form. With
S&G there is no form. You take shaped plywood panels, stitch them
edge-to-edge, then glue them together. What this means is that with SB
you can make smooth rounded shapes. With S&G you end up with angles
running lengthwise for a "hard-chined" shape. Both shapes are
good. Some people prefer a hard-chined boat.
Neither method produces a "better" boat. Strip Built gives more design
freedom (you can make it hard-chined if desired.), and looks nicer
(plywood looks alright but strips of cedar, redwood and pine are
beautiful). SB can make a lighter weight boat but S&G can also be
light.
S&G is easier. There is less setup involved and somewhat easier finish work.
The Process:
The following are outlines for each process:
STRIP-BUILT
=======================================================
The basic process for a strip built kayak is this:
1. Draw out the forms full size,
2. Paste the drawings to cheap plywood,
3. Cut out the forms using the saber-saw or band-saw,
4. Cut a hole in the middle of the forms,
5. String the forms on a straight two-by-four,
6. Lay 3/4" x 1/4" strips on the forms and staple in place,
7. Add strips, gluing edge to edge, and stapling,
8. When stripped all the way around, pull the staples,
9. Plane smooth,
10. Sand smoother,
11. Fiber-glass the outside,
12. Remove the shell from the forms in two halves (deck and hull),
13. Plane and sand the inside,
14. Fiber-glass the inside,
15. Glue the deck and hull back together,
16. Sand,
17. Varnish, go to 16 and repeat until bored,
18. Paddle.
This process shouldn't take more than three months. The weight of these boats
with a good protective layer of glass is 45 lbs or less. Materials cost about
$300 US total.
STITCH AND GLUE
=======================================================
The basic process for Stitch & Glue is:
1. "Scarf" together several pieces of plywood (Make one big sheet out of several
4x8 sheets)
2. Draw the parts full-sized on the plywood.
3. Cutout the parts.
4. Drill small holes along the edges of the parts ever 3" to 5".
5. With wire "stitch" the panels for the hull together through the drilled
holes.
6. Glue the interior seams with a "fillet" of thickened resin covered with
'glass tape.
7. repeat 5 & 6 for the deck.
8. Bond together the deck and hull in a similar manner.
9. Cut the wires and pull them out or sand them down.
10. "Radius" the corners.
11. Glass the outside. (optional but recommend on the bottom)
12. Sand and Paint.
13. Paddle.
This process takes about 1 to 1 1/2 months worth of weekends and evenings.
Weight with glass on the bottom is about 40 lbs. Material cost about $200 US.
SKIN AND FRAME
=======================================================
The basic process for Skin and Frame is:
1. Cut two gunwhale pieces, symmetrical about the grain, from a 16ft. plank.
2. Cut and plane an identical angle in both ends of the two pieces so that when
they are placed in a 'boat' shape, they meet flat.
3. Tie the ends together and establish your shear-line shape by putting spacers
between the two pieces. Peg the ends of the gunwhales together.
4. Cut about 12-15 deck supports to hold the shape of gunwhales. One serves as
a footbrace, one is right behind the cockpit as a back support, and the two
in front of the cockpit should be arched to provide knee room and easy entry.
Peg or mortice-tenon these supports in and lash them to the
gunwhales. 5. Cut slots in the bottom of the gunwhales for ribs.
6. Cut stem and stern pieces from a plank. These should meet the
gunwhales
smoothly and provide an attachment point for the keel. Lash them to the
gunwhales.
7. Steam, cut, and bend ribs. The ribs will establish the bottom shape of the
hull. Peg the ribs into the gunwhales if desired.
8. Cut chine stringers and a keel piece to fit, peg to the ribs if desired, peg
and lash to the stem and stern pieces.
9. Skin the boat with your choice of material.
10. Cut and bend a cockpit coaming, sew it to the skin.
11. Paint the skin to waterproof it if necessary.
12. Paddle.
This is obviously a much-simplified list of steps. It takes about 100 hours to
build a boat this way, about 3 months of weekends. Weight is less than 40
pounds. Material cost is about $200 US.
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