Kayaks You Can Build: An Illustrated Guide to Plywood Construction »

Ted Moores is the bestselling author of Canoecraft. In 1972, Moores pioneered the woodstrip/epoxy boatbuilding system for canoes and, since then, has promoted the fine art of wooden-canoe and kayak construction.

Greg Rössel builds and repairs small wooden boats and is an instructor at the Wooden Boat School in Maine. Rössel is the author of Building Small Boats.

A step-by-illustrated-step guide through the entire construction cycle of building a plywood kayak from a stitch and glue kit. Includes a history of kayaks, choosing a kayak, setting up a work area, tools, tricks, safety and troubleshooting.

Library Journal

Many people dream of owning a boat, and those who are brave enough and have a large work area may want to consider building their own watercraft. According to Moores and Rossel, both boat-building instructors, using a plywood kayak kit is a good place to start because new adhesives allow for less daunting construction. The authors introduce readers to the stitch-and-glue method, where plywood panels are wired together and then coated with epoxy and fiberglass cloth. Half of the text covers the assembly of three commercial kayak kits, providing detailed instructions and information on materials as well as numerous tips and shortcuts. Seeing this process allows potential builders to determine whether they are up to the challenge. This book should be required reading for those thinking of building their own kayak. Recommended for comprehensive public library collections. Copyright 2004 Reed Business Information.

Introduction

1. A Short History of the Kayak
• The Pioneers of Recreational Kayaking
• The Folding Kayak
• Plywood and Strip-Planking
• A Bit on Bytes


2. Choosing the Right Kayak
• Where Will You Paddle?
• Consider Your Skill Level
• Design Considerations


3. Setting Up the Workshop
• Working Like a Professional
• Think Lazy
• Ruminations on a Good Worktable
• Building a Worktable


4. Tools, Materials and Supplies
• Plywood: Join the Marines
• Plan Sheets
• Measuring and Setup Tools
• Cutting and Shaping Tools
• Fastenings and Fastening Tools
• Epoxy and Fiberglassing Materials
• Epoxy Thinners and Solvents
• Fiberglass Cloth
• Epoxy Tools
• Sanding Tools and Materials
• Finishing Tools and Materials
• Safety and Cleaning Supplies and Other Necessities



Twelve steps to a Kayak

5. Plywood Boat-Building Techniques

Joining the Plank Components

• Lining up the Components
• Working with Epoxy
• Clamping
• Butt Joints
• Glass Butt Blocks
• Plywood Butt Blocks
• Scarf Joints
• Scarf Joints in Wide Panels
• Scarfing Sheer Clamps and Guards



Assembling the Hull and Deck

• Drilling Suture Holes
• Making Wire Sutures
• Wiring Panels
• Tacking Planks with Filler
• Filling Wire Holes
• Fillets
• Fillet and Tape
• The EndPour



Fiberglassing the Outside and Inside

• Preparing the Surface
• Positioning the Fiberglass Cloth on the Outside
• The First Coat of Epoxy
• The Squeegee Is Your Friend
• Reinforcing the Stem
• The Second Coat of Epoxy
• The Third Coat of Epoxy
• Sealing Plywood with Epoxy
• Fiberglassing Inside of Hull



Sanding

• Machine Sanding
• Hand Sanding



Installing Trim

• Building a Safe Kayak
• Bulkheads
• Cockpit Coaming
• Hatches
• Steam-Bent Outer Stems
• Guard



Fitting Out

• Seat
• Foot Pegs
• Hip Braces
• Rudder
• Deck Rigging
• Nonskid Area



Finishing

• Super Sealer
• Varnishing and Painting
• Adding Color with Aniline Dyes


6. A Kayak Builder's Journal

The Coho

• Day 1: Get Organized
• Days 2-4: Join Plank Components
• Day 5: Assemble Hull
• Days 6-7: Glue Plank Seams
• Days 8-11: Glass Outside of Hull
• Days 12-13: Assemble Deck Panels
• Days 14-16: Seal Underside of Deck
• Days 17-19: Glass Inside of Hull
• Days 20-21: Join Hull and Deck
• Days 22-24: Glass the Deck
• Days 25-29: Trim the Deck
• Days 30-37: Varnish or Paint and Install Fittings



The Mill Creek

• Day 1: Get Organized
• Days 2-4: Join Plank Components
• Day 5: Assemble Hull
• Days 6-9: Join Planks
• Days 10-11: Glass Inside of Hull
• Days 12-13: Complete Interior
• Days 14-18: Glass Outside of Hull
• Days 19-21: Install Bulkheads, Knees and Carlins
• Days 22-26: Install and Glass Deck
• Days 27-30: Install Trim
• Days 31-36: Varnish or Paint, Install Fittings



The Enterprise

• Day 1: Get Organized
• Days 2-3: Join Plank Components
• Day 4: Set Up Forms
• Days 5-7: Assemble Hull
• Day 8: Glass Outside of Hull
• Days 9-11: Plank the Deck
• Days 12-14: Glass the Deck
• Days 15-16: Glass Inside of Hull
• Days 17-22: Complete Deck
• Days 23-28: Varnish



Glossary

Sources

Acknowledgments

Index