How to Make a Wooden Kayak
Building a wooden kayak is a challenging prospect that requires creativity and skill. For first-time boat builders, a stitch and glue kayak is the easiest and cheapest way to build a kayak. By starting with this model, you will learn kayak-building methods while producing a functional craft.
Things You'll Need
- Kayak plans
- Marine-grade plywood
- Band saw, jigsaw, or handsaw
- Copper wire
- Pliers
- Sandpaper or sander
- Fiberglass cloth and epoxy
- Paint
Instructions
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To build a wooden kayak, you will need a pattern. Plans can be purchased online from companies like Guillemot Kayaks for under $100; some websites will allow an instant download, while others will ship full-size plans. The instructions will include step-by-step directions and patterns for the different pieces of the kayak. Cut out each piece carefully.
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Trace individual kayak pattern pieces onto marine-grade plywood sheets using a pencil. With a band saw, jigsaw, or handsaw, cut out each piece, paying special attention to curves; precise curves are crucial to a well-formed kayak. Be sure to mark each piece with its name and location.
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Using a hand-held drill, make holes along the edge of the seam side of the plywood pieces. These holes will be used to "stitch" the kayak together with wire. Place each hole about 3 to 4 inches apart. If you have two pieces that are identical, place them across a raised brick, weigh them down, and drill through both pieces to save time and ensure equal distances. Drill all holes before beginning; it can be difficult to drill a side of a boat when the opposite side is attached to another piece.
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Cut your copper wire into 4-inch pieces. Referring to the kayak plans, line up the pieces that will be secured together. Thread a piece of wire through the first set of holes and twist the ends together with pliers to secure. Continue down the length of the boat, and go back to adjust wires that have come loose. Repeat this process for both the hull and the top of the kayak.
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Place braces across the width of the kayak. Most kayak patterns will include directions to cut specific lengths of 2-inch by 4-inch wood pieces to act as braces inside the kayak. Cut out these pieces and lay them inside the hull to keep the sides in place. If you have very long or very short legs, consider adding another piece to act as a foot brace when you are paddling.
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Use a plastic body filler or polyester resin to "glue" the seams and make them watertight. Spread the product on the inside of each stitched seam and allow it to dry for the time recommended on the package. If any of the wires are standing out, cut them off and sand down the ends.
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Stitch together the top and bottom parts of the kayak with wire. Place the braced kayak hull on the ground and carefully line up the deck pieces on top. Secure the ends of the kayak together to keep the pieces from moving, and work toward the center using the copper wire pieces.
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Lay fiberglass cloth over the boat and saturate with epoxy; you will likely need to do this in sections to ensure a smooth finish. Allow the fiberglass to cure for at least 24 hours, and trim the excess cloth. After two or three days of final curing, sand the outside and edges, and paint the kayak your preferred color.
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References
- Photo Credit kayak image by Earl Robbins from Fotolia.com
