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I decided to build a kayak out of cardboard using a plywood lamination technique in order to make the cardboard strong enough. Basically cardboard has a grain like wood, so you just change the grain direction with each layer, like they do when they make plywood, and viola, you have "plyboard".
As a cautionary note to those of you ambitious enough to try this yourself, know that it takes ALOT of time, effort, and planing. I managed to go from model and blueprint to full kayak in just 4 days, but know that I lost ALOT of sleep staying up late to laminate layers of cardboard layers, and there were several features that I simply did not have enough time to construct. I spent a few weeks in preparation scrounging around cardboard dumpsters looking for large, pristine (pristine is KEY as we learned) double layer (two layers thick) cardboard. You need ALOT of cardboard, the sheet used to make my kayak measured 6 ft wide by 10 feet long. With four layers to it, thats 240 square feet of cardboard!
Also, you need a large flat space on which to construct your plyboard.
Anyways, the great thing about making your own kayak is that you can make it to any specifications you want, and add any feature you want as well. My brother for instance, said he would have made a flat backed kayak so that he could put a trolling motor on his..... go nuts!
Also, you really REALLY need at least two people to build one of these, three is much better/easier. I was lucky enough to have the help of my Dad, my best friend, and my brother at times....
Enough disclaimer, lets get into the build process!
As a cautionary note to those of you ambitious enough to try this yourself, know that it takes ALOT of time, effort, and planing. I managed to go from model and blueprint to full kayak in just 4 days, but know that I lost ALOT of sleep staying up late to laminate layers of cardboard layers, and there were several features that I simply did not have enough time to construct. I spent a few weeks in preparation scrounging around cardboard dumpsters looking for large, pristine (pristine is KEY as we learned) double layer (two layers thick) cardboard. You need ALOT of cardboard, the sheet used to make my kayak measured 6 ft wide by 10 feet long. With four layers to it, thats 240 square feet of cardboard!
Also, you need a large flat space on which to construct your plyboard.
Anyways, the great thing about making your own kayak is that you can make it to any specifications you want, and add any feature you want as well. My brother for instance, said he would have made a flat backed kayak so that he could put a trolling motor on his..... go nuts!
Also, you really REALLY need at least two people to build one of these, three is much better/easier. I was lucky enough to have the help of my Dad, my best friend, and my brother at times....
Enough disclaimer, lets get into the build process!
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Signing UpStep 1Tools of the cardboard kayak trade....
You will need:
1 gallon of waterproof wood glue - 16-18$ @ Home Depot
paint roller - dollar store is fine, as cheap as you can get it, i got a nice combo pack at family dollar for 8$
paint tray - same as above
paint tray liners (3 or 4 is best) -same as above
good utility knife and lots of fresh sharp blades
skill saw with a fine toothed blade
140 or so bottles of beer, water, or any other small, relatively light weights
aprox. 300 sq feet of pressure sensitive adhesive backed vinyl (glorified contact paper)
masking tape
chalk line
optional;
Drywall square
The vinyl item is a tricky one, you MAY be able to find it by finding a local print shop that specializes in truck or vehicle wraps, and asking them if they have any bad, damaged or miss-printed rolls. It is just the waterproofing layer, so it just needs to be free of holes...
Also, i tested an alternative method of waterproofing, which is much more readily available. Helmsman Spar Polyurethane, make sure its for exterior and waterproof, i almost bought the interior stuff by mistake. Anyways, a couple LIBERAL coats of that (two is the absolute minimum, 3 or 4 is MUCH better) would work just fine. As i was pressured for time (i procrastinate, what can i say?) i opted for the vinyl, and as my father an I both work at a company that manufactures and designs billboard printers, coming by a few used rolls through a little dumpster diving was a piece of cake.
Oh yeah, How could i forget, you need CARDBOARD, AND LOTS OF IT!
1 gallon of waterproof wood glue - 16-18$ @ Home Depot
paint roller - dollar store is fine, as cheap as you can get it, i got a nice combo pack at family dollar for 8$
paint tray - same as above
paint tray liners (3 or 4 is best) -same as above
good utility knife and lots of fresh sharp blades
skill saw with a fine toothed blade
140 or so bottles of beer, water, or any other small, relatively light weights
aprox. 300 sq feet of pressure sensitive adhesive backed vinyl (glorified contact paper)
masking tape
chalk line
optional;
Drywall square
The vinyl item is a tricky one, you MAY be able to find it by finding a local print shop that specializes in truck or vehicle wraps, and asking them if they have any bad, damaged or miss-printed rolls. It is just the waterproofing layer, so it just needs to be free of holes...
Also, i tested an alternative method of waterproofing, which is much more readily available. Helmsman Spar Polyurethane, make sure its for exterior and waterproof, i almost bought the interior stuff by mistake. Anyways, a couple LIBERAL coats of that (two is the absolute minimum, 3 or 4 is MUCH better) would work just fine. As i was pressured for time (i procrastinate, what can i say?) i opted for the vinyl, and as my father an I both work at a company that manufactures and designs billboard printers, coming by a few used rolls through a little dumpster diving was a piece of cake.
Oh yeah, How could i forget, you need CARDBOARD, AND LOTS OF IT!
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You also might glue some wood veneer or something as an outer layer. This way you could simply paint it and have a more abrasion resistant kayak.
Fiberglassing the hull is also a good option for waterproofing. Come to think of it- the fiberglassing would give you a proper sandwich construction kayak. Yehaw. People race those in the olympics etc (it will be a foam core, not made out of cardboard, but...).
Cheers, Christian
And how much did the total cost amount to?
Just ask any manager to leave a note for the third shift crew to set some aside. Or you can call after hours and ask personally. There is a manager in the store 24/7. Hope this helps!!