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is an overview of our wood kayak kit assembly process. |
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| Woodstrip
Kayak |
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The
basic craft is a wood structure covered in fiberglass and sealed
with clear epoxy. The wood provides the shape and beauty of the boat.
The wood also separates the fiberglass layers improving strength
and stiffness. While the fiberglass and epoxy deliver the hull strength
and durability.
The
boat is coated inside and out with epoxy to protect the wood from exposure
and wear. It is important that the entire boat inside and out is completely
coated in epoxy. If there are areas left uncovered fresh water will find
its way into the wood and begin to degrade or damage the wood.
All kayak kit parts are labeled for easy reference
and assembly. |
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| Strongback |
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Before
you begin putting the pieces of wood together to build the kayak
a form is needed to attach the wood strips.
The strongback is exactly what it's name suggests: it's the back bone
that we will use to define the shape of the kayak. It is 16' to 20'
long 8" x 6" stiff box that will hold the inside
forms that define the boat shape.
Every Action Fish kayak kit includes the complete strongback with all
necessary screws, bolts and nuts. Every piece of wood is pre-drilled,
slotted and labeled to allow for quick assembly. We have taken great
care to allow you to quickly get building without having to "create"
parts
and
pieces just to get building.
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| Wood
Strips |
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The wood strips used for the body of the kayak are chosen
for their weight and strength. They are also some of the most well
suited woods for boat building. Western red cedar is the star being
exceptionally lightweight and highly durable in sea conditions.
The
strips are milled with a cove and a bead so they can be joined together
easily and the joint is tight even when the strips are bent
over the form of the boat.
This allows
for a lightweight yet durable boat. The result is a hull
with clear wood strips.
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| Strip The Hull And Deck |
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wood strips are placed around the strongback and boat forms. With
every kit we include pre-cut boat forms.
The boat forms provide the shape of the boat. The
joints are held in place with yellow wood glue. The glue is not intended
to add exceptional strength to the boat, rather it is used to hold
the pieces together until they are coated with fiberglass and epoxy.
Therefore, try and limit the amount of glue you use. The result
is the shape of your boat. |
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| Fiberglass
And Epoxy |
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Fiberglass cloth is used to cover the boat and provide
strength to the hull. Fiberglass is exactly what it's name suggests,
fibers of glass that are woven into fabric. Extra layers of fiberglass
are used around areas of the boat that receive the most stress.
Epoxy is a two part liquid -- resin and hardener
that when mixed together undergo a chemical reaction causing the
material to harden into a plastic like substance. When using epoxy
it's a bit like painting on plastic. The epoxy itself gives little
strength to the boat, rather it is used to bond the fiberglass
to the boat and seal the wood.
Every Action Fish kayak kit includes all epoxy and fiberglass needed
to build your boat. We use MAS epoxy. Hardener, resin, cab-o-sil, wood
flour and metered pumps are all included with each kit.
We use fiberglass which
is woven. The result is fiberglass that easily
conforms
to
the shape
of your hull and deck and ease in building. |
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| Cockpit
And Hatches |
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The
cockpit is built out of thin hardwood laminations held together
with epoxy and then covered in fiberglass. The cockpit is
the area that will receive most of the stress once the boat is complete.
Because of this, hardwood is used. Typically, we use Honduras Mahogany,
though depending on the color desired, there are many woods that are
suitable for use.
Our kit arrives with a pre-formed cockpit coaming so that you do not
need to build any special jigs for your cockpit. Just cut it to the
shape of your hull and insert the cockpit.
The hatches are used to access the front and rear compartments of
the boat where items can be stored. They are cut out of the deck,
then worked to harden the edges and a lip is created to allow them
to slip tightly into place.
Our kayak kits include double hatch gaskets to provide a tight
seal and protect the hatch from the entry of water.
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| Joining
The Hull And Deck |
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| When the two parts of the boat are complete, the hull
and deck are joined with fiberglass tape inside and outside. Once these
pieces are assembled, bulkheads are inserted into the boat to provide
extra hull strength and to divide the boat into three section. After
the bulkheads are installed the finishing process begins with a final
coating of epoxy, then varnish is applied to the boat as a final coat. |
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| Deck
Rigging And Hatch Straps |
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deck rigging and hatch straps are used for fitting out your kayak
and making it seaworthy. Every standard kayak kit includes all
fittings including shock cord necessary for fore and aft rigging,
stainless
steel screws, cap nuts and pad eyes. Also we include all buckles
and straps necessary for securing your hatches in place. |
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| Minicell
Seat And Foot Braces |
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Every
kayak kit we ship comes with a carved minicell seat, hardwood
seat back, hip braces and knee braces. The minicell
foam does not absorb water allowing it to stand up to rugged weather
conditions.
We also include the best quality
adjustable foot braces we can find. They are a bit more expensive but
they pay for themselves in reduced frustration and maintenance. The
foot braces are made of aluminum rails and plastic sliders. The combination
of aluminum and plastic is deliberate so that they will not react with
saltwater and "weld" themselves together over time.
Foot braces are an important safety feature and you should make sure
they are attached before paddling your boat, no matter how great the
temptation to skip this step. When you are mounting the foot braces
take into consideration all of the other people who may wish to "try
out" your new kayak. Our foot braces are adjustable and allow
for about 12" of adjustment.
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