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Building the Kayak - The First Stages

 

The plan gives the offsets to lay out the side and bottom panels on the plywood. Full size drawings of the stem and stern are included to ensure alignment. I took a great deal of care over this stage, because small drawing errors may be magnified at a later stage in the build. The 8ft X 4ft ply panels are butted up end to end and I used a couple of temporary wooden battens to hold the panels in place for marking.

 

First pieces

 

 

 

 

 

I Carefully supported the panels whilst cutting because they are fairly fragile and can snap if left in an unsupported length. Here you can see all the pieces after cutting and then joining. The Frames are laid on the top of the joined side and bottom panels. Note the plywood panels on the ladder sections that formed my building bench.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

butt straps

 

 

 

 

 

 

I used 3.6mm thick plywood butt straps about 75mm wide to join the panels. It is important to ensure that the panels are carefully aligned and assembled as handed pairs. If not, one side will have butt straps on the external faces on the outside! The joints were assembled using a 2-part marine glue which seemed an expensive option. I think epoxy resin would have been just as good.

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