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Step 14: Installing the Cockpit

Glue down the cockpit risers pieces. Mix up epoxy and mix in colloidal silica, cellulose powder or wood flour to make a loose paste-like glue. Brush this the riser piece and around the perimeter of the cockpit. Lay the riser in place. When you have all the pieces in place for one layer adjust the position so it is centered around the cockpit hole.
Apply glue on top of the first layer and on the bottom of the next layer and build up another lamination.
Two layers of riser laminations is the minimum. Three layers will make getting a spray-skirt on-and-off a little easier.
Coat the whole bottom of the coaming lip with a thick layer of thickened epoxy to seal it completely against water. Apply epoxy to the top lamination of the riser and then lay the lip on top.
Check the alignment of all the lamination. Make sure they are all centered around the hole. Check to see the butt-joints between the pieces in each layer are tight.
Add as many clamps around the coaming as you have access to. Keep checking that you don’t knock any of the laminations out of place. Align the tips of the clamps along the inner perimeter, over the riser laminations If you place the clamps too far out from the inner edge you will bend down the coaming lip.
Now, do your best to clean up any squeeze out. Run your gloved finger all the way around the outer edge of the riser laminations, under the lip. Use an acid brush to wipe off any excess glue onto the inside.
<p>Shouldn't it be named a &quot;Plyak&quot;?</p>
<p>I just wrote an article for the Makezine.com blog that discusses the Io childs kayak specifically, it may offer some tips for anyone interested in that boat particularly. http://makezine.com/2016/02/26/building-child-sized-kayak-single-sheet-plywood/</p>
Brilliant! Thank you for sharing your expertise. Someone below was asking about the cost of this build. What do you think would be the feasibility of building this from coroplast? The glassing could conceivably be eliminated entirely.
could anybody if you can use polyurethane glue or any other glue in the step 4 (filling the plywood)? <br>thanks for the plans, the instructions (and the books)
Could you give an idea of what this would cost to build? I'm afraid the f/g would be too expensive for me. Thanks though,
Fiberglass runs from about $5 to $7 per yard. You need about 18 yards. If you keep your eye out on ebay you can find off cuts quite cheap.<br><br>Another option if you are willing to go with alternatives is: just about any cloth can be wet out with resin and bonded to wood to provide reinforcement. So old cotton sheets or muslin could conceivably be used. Historically boats have been covered with canvas to good effect.<br><br>If you are looking to go really alternative, consider using tri-wall cardboard instead of wood then reinforced with fiberglass or muslin. You would want to make sure that all the edges of the corrugation were well sealed. But if you are willing to think &quot;outside the box&quot; a bit, there are many alternatives.<br><br>Lastly, the epoxy resin could be substituted with polyester resin, or going further afield diluting a polyvinyl acetate glue such as titebond or titebond III could be create a workable alternative with a little experimentation.
Guillemot, <br> <br>thank you for this generous instructable! <br>The offsets are very clear and logical. <br> <br>Can you tell us what the beautiful red plywood was used on the child's kayak? <br>Or is it a red stain over a light-coloured ply? <br>I think it's just delicious! <br> <br>Shas
Congrats on being a finalist, and good luck!
I tried to download the .pdf file but it indicates it to be corrupted. <br>
I just tried downloading and it came through without any problem.
The plans at http://www.guillemot-kayaks.com/guillemot/files/Ganymede_Offsets.pdf are also showing corrupt for me.
I tried again by copying and pasting the above URL and it still worked, but I have opened the PDF in Acrobat Pro 10 and re-saved and uploaded the new file. Please let me know if there are still problems
Okay, it seems to work in Chrome. I was trying to download it and open it with Acrobat 9 and Foxit and it didn't work. Thank you. And sorry for the hassle
Awesome Instructable!<br>Is the 7' child's kayak plan also free on your website?<br>I could not locate it.<br>I've dreamed of building one of the Chesapeake Light Craft kits for years.<br>Your Instructable may be the inspiration I need to actually do it.
I just posted the <a href="http://www.guillemot-kayaks.com/guillemot/blog/admin/free_plans_kids_kayak" rel="nofollow">free plans for the kid's kayak</a>. I <a href="http://www.guillemot-kayaks.com/guillemot/kayak/jupiter_point_series/io_childs_kayak" rel="nofollow">call the design Io</a> after another moon of Jupiter. Chesapeake Light Craft has the files to cut an Io kit as well.
Hi and thanks fore this instructablues.<br> I am going to make the Io fore my yongest son.<br> How much fiberglas and epoxy you think I need fore Io?<br> <br> I have made 2 boats: Ponnt Bennet 17,5 fore&nbsp; and Chesapeake 14 fore my 11 year old son.<br> <br> Now this winter I am going to make the 14 Foot Great Auk (got the plans from CLC) fore my 8 year old son but after seeing this instructabule I am first going to make Io for my 5 year old son<br> <br> <strong>Bulding kayaks is realy fun...</strong> <strong>:)</strong>
Thanks!<br>Io makes sense now that you point it out (I thought it was Lo.) <br>Io and Ganymede are now bringing back memories of Astronomy 101.<br>
That is an awesome and well documented build! Great inspiration!
I think I can do this! Thanks! Can you tell me the load limit on one of these? I myself am 240 lbs. WOuld it hold me?
I designed Ganymede to hold up to about 300 lbs. It won't be the most spritely boat with that much weight, but it will float with some room to spare. If you are a really top-heavy body-builder type it might be a little unstable.
Nice job but I prefer to call the stuff &quot;ookie pucky&quot;. Dookie Schmutz would be a little thicker.
great boat and awesome instructable<br><br>Thanks
Brilliant instructable. It's a terrific primer and we've learned about &quot;dookie schmutz&quot;. Thanks a million.
Excellent job, I have studied your designs in the past, we're talking 20 years ago. For those who don't know, Guillemont is a bit of a celebrity in the wood kayak building world. It's an honor to see your work once again.
Lovely instructables, thanks a lot for sharing!<br>I will use some of your techniques for my next project :)
Amazing work!

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Bio: I've been designing and making my own kayaks for over 25 years
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