Month: May 2008

Kayak Construction, more joining

After paddling this morning, I worked on my kit boat a bit. Even though I was much more careful laying down the plastic wrap yesterday, I also used a lot more epoxy, so I still had a lot of epoxy on the “wrong” side to try to scrape down with a cabinet scraper and sandpaper block. As well as that, I also had to spend a lot of time trying to cut down the sides to shave off epoxy on the side (without cutting off any wood) with a carpet knife. It was time consuming work, but mostly it went ok – I think I cut down through the epoxy too far in one place and contacted the fiberglas tape. I also had one place on a very narrow piece (on panel 3) where the tape came right up for about half its width. I’m worried about that, and I wonder if I can glue that back down at some point where I have some spare epoxy. I’m going to have panel 3 out in the next step when I reinforce the bow deck panels, so I’ll have a go then.

After finishing the left side, I staked down the right side panels and taped and glued them. I tried a few different tricks – like to get a much flatter surface below some of the big seams, I nailed them onto one of the temporary forms wrapped in plastic wrap. Hey, by the time I’m finished I’ll probably know how to build this thing! I wonder if I should do another one after I’m done this one?

I also mentioned that I was getting concerned that the mylar sheets were getting a bit ratty? I discovered that you can peel off some of the dried epoxy, and that makes it a lot smoother. So they might do for the fourth side as well.

Paddling this morning

First thing this morning I went for a paddle. I made the mistake of asking to try one of those KayakPro Marlin boats that I mentioned seeing speeding up the creek a few days ago. It was nice. At first it felt quite tippy, but after a few minutes I was paddling pretty hard and not having any trouble staying upright. But there was a bit of an undercurrent of “if you don’t pay attention, it can turn around and bite you”. I was paddling as hard as I could, and it was hardly producing any bow wave at all, unlike the Skerry. When I go hard in the Skerry, I usually find the point where the bow wave gets “big”, and then slack off a bit from there, but without that cue, I wasn’t sure how fast I was going. They told me only to take it for 15 minutes, so I did this little circuit that you can make out of alternate channels in the creek. Towards the end, I was getting tired and I found myself having to think about staying upright more again. I’ve also never paddled a boat with a rudder before, and I had to think about how to use that – evidently the idea is that you can concentrate on doing a power stroke and use the rudder to steer rather than doing a less efficient sweep to steer.

The guy at Baycreek suggested that I come to the Wednesday night racing series and do the course one night with my Skerry, and come back the following night and do it with the Marlin to see how much faster it is. Oh, this could be dangerous – I could really fall in love with this boat. I wonder which boat, the Skerry or the Pgymy, I’ll end up selling to pay for it?

Anyway, 15 minutes wasn’t enough of a workout for me, so after bringing back the Marlin I went for another paddle in my Skerry. It was a beautiful day, and I got a bit of a sunburn on the top of my head.

Kayak Construction, doing the other side

Ok, evidently I lied about it not getting warm enough to do any gluing today. I went to work and did all I can despite the VOB being broken, and when I came home the thermometer in the car said it was just over 70 degrees. Hey, that’s gluing temperatures, I thought to myself. So as soon as I got home I finished trimming and sanding the top side of the left side panels, and then flipped them over.
Continue reading “Kayak Construction, doing the other side”

Kayak Construction, not so bad on the next day

Today I took the weights and the mylar sheets off, and it doesn’t look too bad. The first one I did (the lower one in this picture) has some areas where the fibreglas weave shows through because it didn’t get enough epoxy, and it trapped some dirt in the epoxy in the part that wasn’t covered by the mylar. I tried sanding out the dirt and I think I got most of it. I’m not sure what I can do about the weave showing through, although it’s a lot more visible close up than if you stand back a bit.

The second one (the upper one in this picture) also has a bit of weave showing, but much less. It’s very smooth and shiny and I could almost be proud of it.

The rest actually came out much better. I think you can see a bit of weave on one or two others, but for the most part you can hardly see that there is fibreglas under there.

Today isn’t warm enough to do the other side, but I’ve got to go to work anyway. Tomorrow should be good. I’ll definitely use more epoxy, keep clean bricks close to hand, and use the brush to dab rather than brush the epoxy on the tape.

Kayak Construction, first glue, first problems

The temperature is finally over 65 degrees, so it’s time to start gluing. And it did not go well.

As per the instructions, I mixed up an ounce of epoxy. I painted some on the boards around the seams. Then I cut some of the fibreglas tape and put them down on the wet epoxy and painted some more to wet the tape. Problems:

  • As I painted the epoxy on the tape, the tape kept moving around. I ended up having to hold down the tape with my fingers (in the rubber gloves, of course).
  • As I was painting, one of the boards popped up a bit as a nail came lose. This made gaps and bubbles to painstakingly paint out.
  • Bits of fibreglas frayed off the edges and ends of the tape, and had to be carefully picked out of the epoxy.
  • other random dirt got into the epoxy and had to be picked out.
  • I ran out of epoxy in the middle of it and had to run inside and mix up another ounce.

With that all done, the second part was to cut some strips of mylar and put them on top of the tape, then squeegee it flat, and put weights on them. Problems:

  • I’d put the nails in the boards too close to the seams, so I had to remove them and move them back so the mylar would fit. Several times that lifted one of the boards, ruining all my previous work.
  • The instructions had said to weight them down with bricks. I didn’t think I had any bricks, but I figured all the scrap 2x4s I had could be piled on top. Unfortunately, it turned out that the 2x4s weren’t heavy enough, and things were popping up. With the glue hardening quickly, I had to improvise. I found a pile of half-bricks in a dingy corner of the garage and pressed them into service. Unfortunately they were filthy, and got dirt all over everything. I’m hoping none of it got below the mylar sheets.

    • I’m not looking forward to tomorrow’s reveal to see just how ugly these joints look. Hopefully it will be like my canoe, where I know where every blemish is but everybody else just sees the overall beauty of it.