Category: Kayak Construction

Building kayak(s?)

Kayak Construction: Adding the side panels

Today was a long and hot day. It’s a good thing I’m not counting the hours, because I’m sure I’m taking more hours than what they say it should take. Plus it was hot and humid as hell today, and for much of the work I couldn’t use my stool and had to stand. Looking at the Pygmy Boats site, I’m about done 15 of the theoretical 70 hours (not including some of the optional extras I’ve bought). Today I added the side panel (Panel #2) on each side, and it’s looking a lot more boat-like. Because this is a hard-chined boat, the joint between panel 1 and panel 2 is the chine.
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Kayak Construction, beveling the shear line

I had to work this weekend, which means I didn’t get to spend much time working on my kit, nor did I manage to get out kayaking. Although the weather was mostly shit, so I probably wouldn’t have managed more than a quick dash if I could have gone. Worse, I missed an opportunity to meet up with a couple of people who’ve built a Pygmy Boats kit similar to mine.

The next tasks on my list were to bevel the cockpit reinforcements so that they won’t clash with each other when the pieces go together at an angle, and to bevel the shear line so that when the deck and the hull are put together, they join at the outer ply only. The instructions are a little vague but they suggest that you can do this using a wood rasp, sanding block or block plane. I happened to have a palm sander, and I like a bit of power when I’m going to be removing wood. By holding the sander at approximately a 45 degree angle, and sanding until I saw the glue line between the first and second ply move back to just the right amount behind the sheer line, then I knew I was just biting into the third ply.

I got half the sheer lines done (the side on panel 3) before my hands got so numb I couldn’t continue.

Kayak Construction, gluing the cockpit reinforcement

After a couple of days of it being too cold to glue, yesterday I glued the 4 pieces of cockpit reinforcement that I cut on Tuesday. The instructions said to mix in some wood flour into the epoxy to make it “the consistency of honey”, which is odd because I think of normal epoxy as being about that consistency normally. It also didn’t say how much to mix up, so I did one squirt of resin (1 ounce) and hardener (1/2 ounce).

Before I mixed in the flour, I used some of the epoxy to fix one of the joins where the cloth actually came up off the wood – I crammed in the epoxy with the stir stick and then put the mylar sheet on top and several brick on top. I wasn’t expecting perfection, but I’m hoping it will be less obvious that it was before.

The gluing went ok, but I nearly ran out of epoxy at the end. The first one had lots of epoxy running out the side when I put the bricks on, and the last had absolutely none.

This evening I checked on it and took off the bricks. The join fix came out about as well as I’d hoped – it sticks up a bit and it’s obvious if you look, but I think it won’t be horribly obvious to bystanders. I’m hoping it will be less obvious when it comes time to glass the whole thing. (But if you want to embarrass me, it should be on the left side of the deck very near the stern)

The reinforcement plates had the usual sorts of problems. One of them stuck to the table where the spillage missed the plastic I’d put under it, and I had to scrape off the stuck on table wood with the cabinet scraper. Another one had some scmutz from the brick stuck to the top, and I scraped that off as well. But the one where I’d used up the last of the epoxy seems to be stuck on good and tight, so no worries there.