To provide an initial summary of the working steps involved:

  • Wood planks are stripped with a saw to form long strips measuring typically 18 mm x 7 mm.
  • The strip may be bevelled and faired
  • A set of hull forms (similar to bulkheads) are organised and aligned on a strongback or spine to give the kayak its proper shape
  • Strips are glued together ontop of the forms
  • The hull formed by the strips is faired and sanded for smoothness on the outside
  • Epoxy and fiberglass is layered ontop
  • The hull inner is sanded and epoxy/fiberglassed
  • The strips of the deck are glued onto the forms
  • Fairing, sanding and eopxy-fiberglassing
  • Hatches and cockpits are built, seats installed or built, retractable skegs installed
  • Deck lining planned and attachments made/installed
  • Deck and hull are epoxied and fiberglassed together
  • Sanding, epoxying for a nice finish. UV protection on top.