Introduction  

This manual contains all of the information necessary to make your boat building process enjoyable and successful.  These step-by-step assembly instructions will help you to build your kayak using the “stitch and glue” technique.  

To be of any value, you will need to read, yes read, the manual.  We urge you to read this manual from cover to cover before you start building.  Then, as you build, carefully re-read each step to make sure you understand it completely.  We also recommend that you read the understanding epoxy Manual, included with your kit, before you begin working with epoxy.   

A large number of photos and diagrams add to the usefulness of your manual.  Watch for the following:

This manual gives you recommended techniques.  Experienced builders may find shortcuts or prefer other ways to approach a step.  Each section begins with the following quick reference chart:

 Beginners may find Appendix 2 to be a helpful reference for standard building techniques and tools.  

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1.2     Prepare Your Working Space, Tools and Equipment  

An ideal working space will be a workshop, garage or other clear space of at least 10 ft x 20ft.  (Your boat can be built in less space, but it is not as pleasant an experience.)

The space should be well ventilated and protected from changes in weather, minimum 16 degrees c (60 deg. F).  It will be useful to have a flat workbench or other surface to join panels.  (A temporary surface can be made by laying a sheet of plywood across saw horses.)   

You will need the following tools and equipment at various steps in your boat building process.   

Measurement Units

Throughout this manual, measurements are given in inches, however metric units are used to describe the thickness of some wood.  See conversion chart in Appendix 3, if you are not used to operating in both measurement systems.   

Safety Precautions

PLEASE SEE SAFETY CONSIDERATIONS IN APPENDIX 4 AT THE BACK OF THIS MANUAL.  

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Parts List

Seat       D1    1         inner seat panel                            3 mm (1/8”  ) okoume plywood

               D2    1         second seat panel                        3 mm (1/8”  ) okoume plywood

               D3    1         third seat panel                             3 mm (1/8”  ) okoume plywood

               D4    1         outer seat panel                            3 mm (1/8”  ) okoume plywood

               D5    1         front seat panel                             4 mm (5/32”) okoume plywood

               D6    2         hip brace panel                             4 mm (5/32”) okoume plywood

               D6A  2         hip brace hanger                           4 mm (5/32”) okoume plywood

               D7    1         seat back panel                             4 mm (5/32”) okoume plywood

               D8    1         seat back brace                            12 mm (1/2”) okoume plywood

               D9    2         seat-front hold down tab               4 mm (5/32”) okoume plywood

Hull and Deck

               1A     2         first hull panel – bow                     4 mm (5/32”) okoume plywood

               1B     2         first hull panel – stern                    4 mm (5/32”) okoume plywood

               2A     2         second hull panel – bow end        4 mm (5/32”) okoume plywood

               2B     2         second hull panel – stern end       4 mm (5/32”) okoume plywood

               3A     2         third hull panel – bow end             4 mm (5/32”) okoume plywood

               3B     2         third hull panel – stern end            4 mm (5/32”) okoume plywood

               4A     2         fourth hull panel – bow end           4 mm (5/32”) okoume plywood

               4B     2         fourth hull panel – stern end         4 mm (5/32”) okoume plywood

               5A     2         fifth hull panel – bow end (side)    4 mm (5/32”) okoume plywood

               5B     2         fifth hull panel – stern end (side)   4 mm (5/32”) okoume plywood

               6A     2         deck edge panel – bow end          4 mm (5/32”) okoume plywood

               6B     2         deck edge panel – stern end        4 mm (5/32”) okoume plywood

               7A     2         deck top panel – bow end             4 mm (5/32”) okoume plywood

               7B     2         deck top panel – stern end           4 mm (5/32”) okoume plywood

               7C    2         foot brace backing (optional)        4 mm (5/32”) okoume plywood

Bulkheads

               B1     1         bow (temporary)                           3 mm (1/8”  ) plywood

               B2     1         bow (temporary)                           3 mm (1/8”  ) plywood

               B3     1         front of front hatch (temporary)     3 mm (1/8”  ) plywood

               B4     1         rear of front hatch (permanent)    4 mm (5/32”) okoume plywood

               B5     1         behind cockpit (permanent)          4 mm (5/32”) okoume plywood

               B6     1         behind rear hatch (temporary)      3 mm (1/8”  ) plywood

               B7     1         behind rear hatch – top rib            4 mm (5/32”) okoume plywood

               B8     1         stern (temporary)                          3 mm (1/8”  ) plywood

               B9     1         stern (temporary)                          3 mm (1/8”  ) plywood

Sheer End Forms

               F1     1         bow tip (temporary)                       3 mm (1/8”  ) plywood

               F2     1         stern tip (temporary)                     3 mm (1/8”  ) plywood

Cockpit

               C1A  2         top coaming     (bow end)             5 mm (3/16”) okoume plywood

               C1B  2         top coaming     (stern end)           5 mm (3/16”) okoume plywood

               C2A  2         base coaming  (bow end)             18 mm (3/4”) okoume plywood

               C2B  2         base coaming  (stern end)           18 mm (3/4”) okoume plywood

Hatches

               HIA    1         front hatch bottom strip   (bow)    6 mm (1/4”) okoume plywood

               HIB   1         front hatch bottom strip  (stern)    6 mm (1/4”) okoume plywood

               H2A  1         rear hatch bottom strip  (bow)      6 mm (1/4”) okoume plywood

               H2B  1         rear hatch bottom strip  (stern)     6 mm (1/4”) okoume plywood

               H3     2         front hatch cover                           4 mm (5/32”) okoume plywood

               H3A  1         front hatch positioning bar              4 mm (5/32”) okoume plywood

               H4     2         rear hatch cover                            4 mm (5/32”) okoume plywood

               H4A  1         rear hatch positioning bar              4 mm (5/32”) okoume plywood

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SECTION 2      SURFACE PREPARATION OF YOUR PARTS  

2.1       Part Numbering

Part numbers are pre-stamped to indicate the interior surface of each piece (these stamps will eventually be hidden on the interior of the kayak).   

If you prefer the grain pattern on the stamped side, feel free to use this side as your exterior (visible outer) surface. 

·        first, (in pencil) mark the part number on the side you want as your interior surface;

·        then, (using 150-180 grit sandpaper) gently sand off the pre-stamped part number from the side that will now be your exterior surface.  

2.2       Cutting Nubs and Marking Tabs

See the Diagram 1 on the next page, to understand the difference between cutting nubs and bulkhead marking tabs. 

Each small “cutting nub” will need to be sanded off the raw wood pieces, in the upcoming steps.  

DO NOT CONFUSE the cutting nubs with the “marking tabs”.  The TABS are ⁵/₃₂” (4mm) wide; they indicate the position of bulkheads and the seat riser (D5).  

Note:  Disregard the marking tabs (2 of them) on part D4.  These must be sanded off.

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For each piece with a marking TAB (except D4 noted above):

·        Use a pencil to draw two parallel lines 1½” long on the panel.  The lines must be on the interior surface.  These little pairs of lines will mark where the bulkheads are to be installed.

·        Once your pencil lines are made, the marking TABS will need to be sanded off the raw wood pieces.   

 2.3     Sanding the Raw Seat Panels  

Begin with the seat, to gain practice for more visible parts to come later.  

SECTION 3      JOINING THE PANELS