Building Our Kayaks

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The story of our boats begins with two women in my life, my boss at work and my wife. The stories I brought home from work about my boss’s new kayaking adventures awoke a latent yearning in my wife to try paddling. After both of us taking a lesson, we were ready for more and that led to finding kayaks. My first plan was to build a strip built for myself and find a plastic one for my wife. But some things happen that are just meant to be. A salesman listening to my plan, asked me if I had looked into stitch and glue kayaks. They had the look I wanted, and the cost and time investment in stitch and glue boats would allow me to build two, instead of one. A visit to the Newfound Rendezvous at Wellington State Park, Bristol New Hampshire, in the fall of 2003 gave me an opportunity to paddle strip and stitch and glue kayaks, as well as observe experts in the process of building wooden kayaks. You can watch the rest of the story unfold in the pictures that show the process of building the boats.

 Notes: Pygmy Kayaks - Model: Osprey Standard (Loa15’8”; Beam 24”, Depth 12”; wt. 38lbs.) Place of construction: Since my mother-in-law had moved in with us, her house, just a mile from ours, was vacant. The walkout basement was ideal and converted easily into a workspace. Additional lighting, plastic to cover the floor, and a ping-pong table that I extended to 16 feet table were helpful.

Stitch and Glue kayaks are made up of panels of marine grade plywood nominally 4 mm thick. The panels are stitch together with wire staples to hold them in place until they can be glue with epoxy. Once glued the wire staples are removed. The joints are filled and sanded smoothed and the hull and deck are cover with fiberglass and then coated with epoxy. Additional coats of epoxy are applied to fill the fiberglass. To protect the epoxy several layers of varnish are applied.

The following links take you though my kayak building project.

Glue up Panels:

Day 1
Day 6
Day 8
Day 9

Wiring Hull together

Day 12 - 1
Day 12 - 2
Day 13
Day 14

Inlays

Day 19
Day 28

Fiberglassing Hull

Day 33 - 1
Day 33 - 2

Starting Deck

Day 35 
Day 40
Day 48
Day 63
Day 68

Finishing UP

Day 77
Day 91
Day 123
Launch Day