- Several pieces of 4X8? plywood boards are added up to form one large sheet.
- The parts of the kayak are drawn on this sheet in actual dimensions.
- The parts are cut out from the sheet.
- Along the edge of each part, numerous 3-5? holes are punched.
- The hull is assembled by passing wire in the holes.
- The inner line of stitching is glued up with a resin and further sealed with a glass tape.
- The same procedure is repeated for the deck.
- The deck and the hull are assembled and glued in the same way as indicated above.
- Wires are removed by dragging them out and/or sanding them.
- Fiber-glass is applied on the outside.
- General smoothening is carried out. The exterior can be painted.
- A trial can be carried out in water.
This method would take 1-1 ? months to complete, if one works only on evenings and weekends. Time-taken could be considerably less if one works full time. The total weight of the end-product is around 40 lbs. Total cost of construction would be around $200.
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