Building a Kayak

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There is a wide range of pre-manufactured resin and fibreglass kayaks available, however it is perfectly possible to build your own craft, especially the larger, ocean-going and touring designs. You need some time and patience and a bit of space, but it’s nowhere near as difficult as it might sound at first, and it’s actually quite cost-effective. Another benefit of building your own kayak is that you can adjust the design to your exact specifications and requirements. You can include more leg room or a wider cockpit, or you can alter the shape, affecting the hydrodynamics and handling of the kayak to suit your own preferences and paddling style.

There are three common methods of kayak building – strip building, stitch and glue and skin on frame.

Strip Built Kayaks

In this method, a jig with a series of forms (usually 12) is set up. Strips of wood (typically pine or cedar) are stapled across forms and glued together. The hull and the deck are built separately, but on the same forms. Then the forms are removed, the interior of the kayak is coated with epoxy and the two halves are joined together.

This method of building will result in a very strong, fairly light and very attractive looking kayak. The wood is fully covered with fibreglass and epoxy to provide water-tightness. The building technique allows a great deal of freedom to modify the design or to add decorative patterns.

Stitch and Glue

Occasionally referred to as ‘tack and tape’. Flat plywood pieces are cut to shape, then temporarily stitched together using copper wire, or cable ties. The sections are then permanently fixed in place and the whole kayak is coated with epoxy and fibreglass for strength and water-tightness. This is a relatively fast method of building, but there is very little scope for modification, either to change the hydrodynamics or the aesthetics of the kayak.

Skin on Frame

Otherwise called ‘wood and canvas’, this building method involves stretching nylon or canvas over a frame, similar to the way in which some old aircraft were built. Epoxy is then used to provide rigidity and water-tightness.
Whichever method of building you opt for, you will need basic hand tools and a few ordinary power tools (particularly an orbital and a belt sander) and a space to build in. Most touring kayaks are longer than a single car garage, so measure up before you start. It is also worth considering that building a kayak will produce an enormous amount of dust (especially if you are constructing a strip built craft) so it’s best to have a separate area for building.

Epoxy can be easily sourced (although usually from commercial suppliers rather than hardware stores) and is not difficult or dangerous to work with, providing that the manufacturer’s instructions with regard to storage and usage are adhered to.

Your finished kayak will be completely comparable to a pre-manufactured kayak in terms of strength, hydrodynamics and stability and many kayakers prefer to build their own craft as they can then modify them to suit their frame, paddling style and personal taste. Kayaking is one of the greatest freedoms and there is no greater feeling than paddling a kayak that you have built with your own hands.

This article was written by John Parry, of www.highseakayaks.com High Sea Kayaks supply the ultimate complete guide to strip building and several strip building form kits.