- A life-size outline of the kayak is made and pasted onto low-cost plywood.
- The plywood is cut out according to the outline using saws.
- A hole is cut in each of the structures thus formed.
- The structures are aligned on a two by four basis.
- ?? X ?? plywood bands are laid on the structures and nailed up. Glue is added to seal the bands and the structure, thus forming a shell.
- When the structures are completely covered with bands, the nails are removed.
- The surfaces are smoothened by sanding.
- Fiber-glass is added to the exterior.
- The shell is separated from the structure in two halves: the deck and the hull.
- The insides of the shell are also smoothened.
- Fiber-glass is added to the insides as well.
- Both halves of the shell are put back together and pasted up.
- General smoothening is carried out.
- The end-product is varnished and smoothened repetitively until the desired outlook is obtained.
- A trial may be carried out in the water.
Typical time-needed for completing a kayak by using this method is about three months. The total cost of the kayak comes to around $300. The weight of the end-product comes to around 45 lbs.
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