Category: Kayaking

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.

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.

On Monday I turned over the panels to do the last side. Once again, I had to do a lot of scraping with a cabinet scraper to deal with epoxy that had seeped under the panel, and cutting with the carpet knife to try to restore the original edges of the piece. Rob came over to see how it was going, and it was good to have somebody to talk to while I worked, although it did distract me. I actually mixed the epoxy and was getting ready to apply it when I realized I hadn’t put any plastic wrap underneath, and was in danger of sticking the pieces to the work bench. Fortunately with two of us working it didn’t take long to put the plastic wrap under.

This fourth side benefited from the experiences from the other three, so it went pretty quickly and well. The only problem was that it also was harmed by how ratty the mylar sheets were – I got some voids because of gunk stuck to them, and because they’ve started to turn up at the edges a bit. Definitely next time I’ll buy enough mylar to use new ones each time.

Tuesday I finished that job, again with lots of cabinet scraper and sanding block and carpet knife action. And it was too cold to epoxy, which was just fine because I spend another half hour or so trimming the pieces that are going to be glued under the cockpit to reinforce it. It’s kind of strange that the kit comes with all these CNC cut plywood pieces, and then just two chunks of uncut plywood and instructions to cut the reinforcement (and later the seat) out of them. You’d think they’d cut all of the pieces.

Next job is gluing those pieces on, and then bevelling the shear edges. I’m not 100% sure how I’m going to do that. I suspect a Shure-form tool would be too agressive.

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.