Work from 7/5/2008 through 7/26/2008

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This was the first kayak where my customer lived close enough that he could stop by periodically.  At one such meeting we went over the layout of all the deck lines and hardware.  We marked the physical locations directly on the deck (recently fiberglassed).   It was a great experience.  We accomplished more in a 3 hour meeting than in weeks of e-mails.  All that’s left to complete the “Azure” is to run the final decklines, make/install the carbon fiber toggles and foam out the cockpit. 

We kept the hi-techlook going by using carbon fiber tubes for the grab toggles.  They’re not lifting handles!   To make the tubes I basically followed the directions on the Soller Composites website and used their biaxial carbon fiber braid and heat shrink tubing. First I made a mandrel (mold) from a piece of 3/4″ copper water pipe.  I polished it up, covered it with petroleum jellly (Vaseline) and then tape a piece of clear PVC over that for the final form release. I then laminated the mandrel with 4 layers of  2″ diameter braid.  The heat shrink tubing then squeezed most of the extra resin. The next day I cut off the heat strink and pulled the shaft off of the mandrel.  The toggles were cut to length, sanded smooth, drilled to accept the cord and then clear coated with Perfection Varnish.  They were attached to the ends by a section of 3/16″ cord pulled through double-drilled holes in the ends of the kayak.  They’re held with stopper knots inside the toggle.  Simple and very effective.  Each toggle is about 1″ (26.7 mm OD) in diameter and has walls about 0.070″ (1.8 mm) thick.  Each toggles weighs about 28 grams (about an ounce).

For footbraces the fore bulkhead was padded with pieces of minicell.  Five layers of differing thickness allow 6″ of foot brace adjustment in about 3/4″ increments.  Super-comfy and simple.

I normally also hand-deliver my boats if possible.  My customer offered to pick up the boat the shop.  We did the deck lines together.  Even with our prior meetings we still changed them a few times before tying them off.   Before we tied them off we applied some clear protective anti-scratch tape to select areas of the deck that would be subjected to wear.  It’s normally used on off-road trucks and cars.  The perimeter line is 3/16″ polyester Sportcord.  The bungees are 1/4″.

While he was there we also foamed out the cockpit.  Most the time was spent padding out the thigh-hooks.  They ended up being a bit too small so we glued on some scrap carbon-fiber sheet and extended them forward.  They were then padded out with minicell.

Completion!!  Finished weight of 39 pounds (17.7 kg).  It came in a bit heavier than we wanted.  It’s still respectable for a composite hi-performance sea-kayak.

We didn’t have time that afternoon for a proper maiden voyage so we moved the “Azure” outside for a few beauty shots.   Lena was taking her nap so couldn’t sit in the boat (she IS our official boat tester).  Danielle took over that duty.  She really liked the seat.

After my customer left I cleaned the shop and stored the strongback to await the next kayak…  For now, I need a break!

Total Construction Time: 151.67 Hours  (It was about 30 hours over my original estimate… oh well.)

I do have another project lined up.  It’s a bit different and not a boat: an acoustic 6-string guitar.  I’m building it as a Christmas gift for my in-laws.  Should be a nice change of pace.  No epoxy either!! =D