Instructables
Picture of Turn your office into a kayak

In an effort to explore low cost and sustainable ways of taking to the waves, I have developed this kayak build (based on a traditional Inuit Qayaq), which uses or rather re-uses the most readily available materials. This is instead of relying on expensive and polluting polymers, exotic plywood or even sealskin and whale ribs which make sense in the arctic, but not most other places. My choice of materials then was: suits, desks and computers.

The build uses a traditional 'skin-on-frame' method, which depends upon long batons pulled together at bow and stern and spaced in between with bulkheads. These wooden parts were made from a solid wood desktop. They were lashed together with wire stripped out of computers.

The frame is covered with a 'skin'. I made this from unpicking business suits and sewing them into a large sheet, wrapping around the frame and waterproofing it with an oil/wax mix.

The plans for dimensions were loosely based upon the excellent Yostwerks sea bee. That site can be found through this link:

http://yostwerks.com/WoodSOFMain.html

 
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Step 1: Source and cut solid wood desk

Picture of Source and cut solid wood desk
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I searched local shops and house clearances, but in the end had to buy a locally located desk online (through a popular internet trading site). Solid wood desks are not easy to find. You can't use particle board.

Cut the desktop into strips. The size of the desktop will determine the length of the kayak. You will need five or more lengths of wood. I was able to cut fifteen batons from my desktop and subsequently joined the batons into lengths of three giving a total of five bits of wood a bit over 15 foot in length.

one (sturdiest) length is for the keel. Two for gunwhales which edge the deck of the craft. at least two are for the 'stringers' that make up the rest of the hull line.

Step 2: Steaming

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You will most likely have to steam and bend the batons. You can use a
kettle with steam pipe into a long tube (eg a heating tube). Insulate it to get it hot enough then bend the wood once steamed. Steam is hot! Don't burn yourself or try this if you aren't sure about how to use this equipment safely.

Step 3: Mount on a 'strongback' and cut and fit bulkheads

Picture of Mount on a 'strongback' and cut and fit bulkheads
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Next cut the five bulkheads (aka cross-sections) to the correct size and shape. All five are (half) shown on this plan up to their midline. In other words you have to double the shape on the other side of the dotted line as if it were a mirror, then you'll get the complete shape for each of them. You'll see how they should look from other images later in the build.

Once you have the bulkheads and stringers/keel etc you will need a strongback to fit the lot together on. A strongback is a firm base which you attach the bulkheads to - at the right spacing and height. I used the rest of the desk to make mine.

Attach the bulkheads at the right height (the bottom dimension on the plan) above the line of the strongback. You can do this with temporary blocks, which will also hold the thing in place.

The bulkheads go at the following spacings (distance in cm from bow): #1 at 61; #2 at 122; #3 at 173; #4 at 251; #5 at 318. stern is at 396 cm from bow.

Then you can fit the stringers, keel and gunwhales on, holding them temporarily with elastic chords or tape.

Step 4: Lash together

Picture of Lash together
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I used stripped out wire from the computer to last the batons to the bulkheads. You can also see where I put slight cuts along them to help smooth bending without breaking (this is called kerning I believe). I needed to reinforce the cross-sections, but this depends on the wood you have available to make them.

Cut boards for stern and bow, cutting and lashing the stringers, keel and gunwhales to fit.

You have nearly finished making the frame. You still need to add a deck stringer from near the bow to the top of the thrid bulkhead. You can see this space where this will fit in these images. Exact dimensions are less critical for this.

Step 5: Skin

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Acquire a number of discarded suits ('lounge' suits aka business suits). 3 should be enough. Using a stitch ripper (a small prongy thing which unpicks stitches) you can fillet the suits into useable panels.

Sew these together with waxed thread.

Wrap around the frame and sew up the skin removing any excess.

Step 6: Waterproofing

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You can 'dope' your skin with a number of different materials. Gloss paint will work, as will many glues. Linseed oil is a traditional material - used on coracles and curraghs - although pitch (from trees) is more usual.
I used linseed oil mixed with a little wax. Applying the mixture hot will help it soak in. Several coats may be needed with drying time between.

Step 7: Post-beaurocratic jetsam takes to the waves

Spare materials can be used in other ways to make sure your project has minimal waste.

Ensure you know what you are doing if you take this craft into water and wear a floatation device.

ucoopa15 months ago
Great idea - awesome - we are going to make some with our scout group - maybe with a recycling theme twist though ....

=+]
eng_Andy5 months ago

I like this modern-survivalist art theme.

I've been wanting to build a SoF outrigger canoe, but I too don't want to have old trees cut down just for the purpose, and I happen to have some scavenged pallet wood here, but joining the beams strongly enough without using toxic adhesives has been a sticking point for me.

Could you please go into more detail on the method that you used to join several beams on end into longer strips?

I'm thinking just building the outrigger(s) might be a good start to test the strength of recycled pallet wood (since it is usually weather-worn and has nail holes in it, of course).

goatboy8255 months ago

I like it. Functional statement of the times.

Next, a harpoon from a broom handle and a steak knife? Then you can sell the freshly caught three-eyed irradiated mercury bearing tuna at the farmers market for use in a micro-processor.

Re-purpose all of life and you will find abundance.

iamuke5 months ago

Very nice. Yostwerks is the essence of DIY (I built a Sea Ranger), and you just made it even better. Great job!

vitex5 months ago

That's insane - in a good way! I think we need a few artistic responses to a world that's gone crazy. The idea of ripped up business suits being used as kayak material reminds me of "Nothing but Flowers" by Talking Heads. This is the essence of survival thinking. I've built a couple of stitch-and-glue kayaks, and the amount of petrochemical-sourced epoxies and things you have to use always freaks me out. Of course, it's all proof-of-concept stuff - it'd take quite a bit of finessing to get close to the exquisite symmetry of a kajak or baidarka, or of a polynesian outrigger canoe, so best we get started eh?

24Eng5 months ago

What made you decide to tackle this project with such strange materials?

johntonta (author)  24Eng5 months ago

Well in one way these are the least strange materials possible. Right now I'm sitting at a desk, using a computer, though not wearing a suit. When people think of locally available materials, then that isn't going to mean stuff from forests for most people in the world (majority of worlds population is urban now). Look around right now. What's most to hand?

I follow your logic entirely.

"I want to make a kayak - what do I have available, at hand, to make it from?"

It never ceases to amaze me at how people kind of lack the broader perception - like they think growing tomatoes in a plastic bucket with a few drainage holes in the bottom, instead of a big plastic flower pot, is a quantum leap up or forward in logic.

Like "Oh my god - I didn't know you could grow tomatoes in plastic buckets with some drainage holes in the bottom - I thought you had to use plastic flower pots."

Wow - Awesome etc....

I tend to be a bit neurotic about durability and protecting the wood against rot and all, and choosing fabrics that are reasonably durable when wet.

I guess the issues of daily use and or seasonal use, and extracting lots of life span out of the effort come to mind.

Did you choose for fabric types, like polyester suits, or poly cotton / poly wool blends / or woolen?

csokl5 months ago

Great ideas, thanks

AKDoug5 months ago

That is amazing. The traditional Inupiat word for kayak is "kayak." Ray Mala introduced it to the world (via Hollywood) in the... 30s?

Very unorthodox building materials.. but I approve, it's so unique you just can't say no to it. Very nice build, mate. As a kayak enthusiast who's currently without a kayak this has me looking around my bedroom thinking what I can turn into a new little boat or kayak for myself

This is the very essence of the original kayaks. They used the materials that they had on hand. Hundreds of years ago, the Inuits, did not just run to Home Depot for materials.

stottsmonkey5 months ago

very innovative maker-style re-purposing. great illustration of true recycling!

Gregbot5 months ago

sweet!

Thank you for this instructable, I guess I won't make a kayak anytime soon, but I had a good laugh seeing you use the materials you used. And besides my laugh, it looks like a great build.

24Eng5 months ago

Right on. If this idea had occurred to you in the bathroom it could have been made from shower curtains, towel rods and a toilet seat!
I think it's wonderful that you're showing people boat building isn't about obtaining expensive and high tech materials or century-tested rustic materials.

this is what instructables should be all about. Well done, more like this please

craftclarity5 months ago

I applaud this as one of the more interesting examples of creative reuse I've yet seen on Instructables.
There are more than a few kayak enthusiasts around Instructables who would appreciate your unorthodox approach.

Bravo!

johntonta (author)  craftclarity5 months ago
Thanks for your comment!
John