Stitch and Glue Kayak Method

By admin on January 5, 2009

Stitch and Glue Kayak Method

  1. Several pieces of 4X8? plywood boards are added up to form one large sheet.
  2. The parts of the kayak are drawn on this sheet in actual dimensions.
  3. The parts are cut out from the sheet.
  4. Along the edge of each part, numerous 3-5? holes are punched.
  5. The hull is assembled by passing wire in the holes.
  6. The inner line of stitching is glued up with a resin and further sealed with a glass tape.
  7. The same procedure is repeated for the deck.
  8. The deck and the hull are assembled and glued in the same way as indicated above.
  9. Wires are removed by dragging them out and/or sanding them.
  10. Fiber-glass is applied on the outside.
  11. General smoothening is carried out. The exterior can be painted.
  12. 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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