Often, in my building career, I've put deadlines on a project. I have never put so much pressure, on myself, as I did with this one. After a month away from the project to do fulfill my duties for work, it was time to get back to work. A phone call from Deb was the catalyst for one of those "Oh boy, what have I done moments". We set a date for the final fitting, test paddle and delivery of the boat. I had just under four weeks to get it done. A look at the calender to create a plan, revealed that I had really backed myself into a corner. The paint process would take approximately ten days for five coats of varnish, primer and five coats of paint. The decision to go with yellow on the hull was important as far as visibility and safety. The flip side is, yellow covers poorly. It takes two more coats than usual for coverage. Two more coats means two more days needed in a very tight, if not impossible deadline. The other issue, the fiberglassing process of the deck and hull bottom. Normally two or three days for each to achieve a finish ready surface. Half of my time was accounted for already. It was time to get creative.
Catching up on construction
Since Peel Ply would not conform to the recesses, I had to fiberglass them prior to the rest of the deck. A modest overlap at the edge would ensure they were the were strong and would properly protect the corner.
Next the fiberglass cloth, resin and finally peel ply were applied to the surface. This was a marathon glassing job, that could not be interrupted once started. Thankfully, I had some help from a co-worker, so I could go home a decent hour. The good news as it all worked as planned. If not carefully applied, Peel Ply can also trap air and infuse it in the resin, not a good thing. After obsessing over every little imperfection, I was satisfied that it would come out as envisioned. The payoff came the next morning. I arrived and started peeling back the release cloth to reveal a finished deck. I had just gained two days back in the schedule.
All that was left on the deck was to trim, the openings, and overlap on the hull. The deck fittings needed to be cleaned out and resealed with another coat of resin.
The bottom of the kayak needs to be able to endure the cumulative abuse that it will be subjected to over the course of the expedition. Rocky beaches, surf landings and a combined weight of 300lbs of paddler and gear, could spell disaster. The decision was to add another layer of 6 oz fabric to the bottom. It was "canted" to add strength. The threads of the two layers would be in four different directions, doubling not only the thickness, but the number of thread intersections for maximum strength. Peel Ply was utilized again, to keep the resin to cloth ratio at the optimum 50/50 proportions. The upside was again, two days saved in construction. The cloth was also wrapped around the chine, an area that often gets overlooked for reinforcement, but receives a lot of abuse when landing on rocky beaches.
The coaming was next on the checklist. I do things a little differently, by molding the risers to the deck. Plastic is placed between the risers and the deck surface to prevent adhesion. Once cured, the risers can be popped off and sanded smooth, before final assembly. Why is this important? A smooth surface will help the spray skirt last longer. The extra steps, not only serve a purpose ascetically, but they have a practical purpose as well.
The Coaming was installed and it was almost time to conclude construction. All that was left was some finish sanding and fiberglassing left before moving on the the paint and varnish stage. I put a generous round-over on the coaming. The boat gets lifted from this area and sharp edges are hard on weary hands. The paddlers body comes into contact with this are as well. Having a soft edge will lessen the chance for injury if things get rough.
The final push
With the pick up date looming ever closer, my days got longer. The varnish and paint requires twelve hours, between coats, to properly cure. There was no way to get around this. Early mornings and late nights were the norm as five coats of varnish, two coats of primer and 4 coats of bright yellow paint were applied.
To better protect the keel at the ends of the boat, Dynel rub strips coated with graphite and epoxy were applied. Again, this increases the durability of two high wear areas.
Rigging time, the race is on!
Next up was rigging the boat. The rudder, hatches, seat board and all deck rigging needed to be installed and sorted out. With only two days left, the planning was all starting to pay off. Every detail had already been addressed in my mind. Execution of was all that was left before the boat was done.
The seat board was an interesting design challenge. An emergency water bladder was stored below the seat. This was Deb's design idea, I just added a high tech twist to it. To pull this off, a platform was constructed out of carbon reinforced plywood. Simplicity was again the theme as it was strapped to the floor for easy access to the bladder. The test paddle proved insightful, as the bungees were inadequate. Deb was being lifted up as the water sloshed from sided to side. She has since replaced the bungee cord with straps.
Final Thoughts...The power of "Yes"
Looking back at this project, it started with just a simple "yes". An idea and an open mind to the possibilities, was all it took to put things in motion. As the build progressed, the momentum of the expedition increased. One "yes" led to another and the possibilities became more of a reality. The Paddlesports industry was the first to jump on board. Donations of components for the build was just the beginning. It is amazing what happens if you just ask. Seeing the generosity that surrounds this program is heartwarming. The spirit of giving is alive and well. I may not be paddling this boat, but I will be there in spirit. I put my heart and soul into every project, this one was no different. I owe a special thanks to Tim at Paddlers Supply and Ryan at Sealect Designs. They were quick to say "yes" when I needed components. A special thanks goes to Deb for trusting me with her boat. This project has been a turning point for me both personally and professionally.
For more information on Deb's journey:
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