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  •  Sawfish, an unsinkable, lightweight, foam kayak (23 lbs). Free DIY kayak plans, the hardware store boat

    Thanks rowerwet. The seat is raised 3.25" - easier fishing! I will have to look again to see where I saw 2" foam but off the top of my head I think it was Home Depot. Shipping for a 2"x4'x8' sheet was like $56 and the sheet cost $32ish. LOLThe footwell is 20" front to back, 5.75" below the top of the gunwhales.My dimensions are:12' 1" longNose (12" from bow tip) is 12"Width at center is 27.5"Hip (widest point - should always be aft of center) is 28", 54" from the stern. This is also center point of the seat. The sweet spot ended up right at the hip where I wanted it - nailed it!I built in 2.25" of rocker staggering wedges and added maybe another 2.25" with the surform. On the bottom I added a central tapered rib just on th...

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    Thanks rowerwet. The seat is raised 3.25" - easier fishing! I will have to look again to see where I saw 2" foam but off the top of my head I think it was Home Depot. Shipping for a 2"x4'x8' sheet was like $56 and the sheet cost $32ish. LOLThe footwell is 20" front to back, 5.75" below the top of the gunwhales.My dimensions are:12' 1" longNose (12" from bow tip) is 12"Width at center is 27.5"Hip (widest point - should always be aft of center) is 28", 54" from the stern. This is also center point of the seat. The sweet spot ended up right at the hip where I wanted it - nailed it!I built in 2.25" of rocker staggering wedges and added maybe another 2.25" with the surform. On the bottom I added a central tapered rib just on the forward 2/3 of the boat and cut channels into the tail to give it more effective rocker without losing stability.I was laying back stretched out when my feet were on the bucket. ;)I finished up the footrests and sanding today. Tomorrow I will seal up the deck and she is done.An aside while I am thinking about it - I think vacuum bagging the foam while gluing it instead of stacking weights on it will work better - even pressure and it should help spread the adhesive better. I am bagging the next one and will report how it goes.Record build time came at some cost to quality of the finish. I wish I had not gotten impatient to go fishing and had spent more time polishing up the hull before wrapping and painting. I did not do a good job sanding it or trimming glue, so it is not a very smooth finish on the bottom as you can see. I plan to make the deck look more than beautiful to redeem myself. I am also considering stripping the hull and doing it right so the whole boat will be beautiful. I honestly did not expect the boat to perform as well as it does. My last yak was a Tarpon 150 and this boat rides and handles every bit as good as that kayak. Great boat. Thanks again! More photos coming.

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  •  Sawfish, an unsinkable, lightweight, foam kayak (23 lbs). Free DIY kayak plans, the hardware store boat

    I took my yak out this morning to test it before wrapping it up. It works great! It is much faster than I expected. I was able to paddle into the wind with ease. It is not stable enough to stand on as I had hoped, but plenty stable seated and she tracks laser straight. I found a stadium seat for $20 and mounted it with electrical conduit clamps so I could slide it fore/aft and find the sweet spot - worked like a charm. I need to make a few tweaks here and there, but overall I am very happy with it. 1 thing I wish I had done was fish from it before cutting my storage and bucket spots. I would rather have the tackle box closer than the dry storage on the bow. It definitely needs a skeg or a rudder to keep the wind from turning it around while fishing. This was my first time in a kayak wit...

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    I took my yak out this morning to test it before wrapping it up. It works great! It is much faster than I expected. I was able to paddle into the wind with ease. It is not stable enough to stand on as I had hoped, but plenty stable seated and she tracks laser straight. I found a stadium seat for $20 and mounted it with electrical conduit clamps so I could slide it fore/aft and find the sweet spot - worked like a charm. I need to make a few tweaks here and there, but overall I am very happy with it. 1 thing I wish I had done was fish from it before cutting my storage and bucket spots. I would rather have the tackle box closer than the dry storage on the bow. It definitely needs a skeg or a rudder to keep the wind from turning it around while fishing. This was my first time in a kayak with no rudder so learning took place. I put plywood on the stern deck for mounting a rudder or trolling motor. It glides so well paddling I think I am going to add a foot control rudder and forget the motor. I am going fishing in it again tonight, going to make some mods tomorrow and finish it up this weekend. I caught 4 bass on her maiden voyage, so she earned the name Bountiful Harvest. I will post more pictures when she is 100% complete. Thanks again for the killer instructable!

    I would have took it out yesterday but the only public place to launch that I know of was closed yesterday. When it is completed it will have taken me about 2 weeks, but I am semi-retired & self-employed so I was able to devote a good amount of time to it every day. When done I estimate it will have taken me about 60 hours to build, but a WHOLE LOT of that time was spent gluing together 3/4" foam and positioning supports. The $56 cost for shipping the 2" stuff would have been well worth the money, in retrospect.

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  •  Sawfish, an unsinkable, lightweight, foam kayak (23 lbs). Free DIY kayak plans, the hardware store boat

    My kayak is almost done. Lots of lessons learned! I will do whatever I must to get the 2" foam next time. Sticking together all that 3/4" stuff was time consuming, less structurally sound, and upped the cost from using 5 times the amount of glue. Glue: 3M Super 77 works well if you stack on a lot of weight and give it a good cure, 3M Super 90 melts XPS. I also discovered there are many types of foam labeled "XPS" and they have very different properties. I discovered this 3/4 of the way through my project when the good idea fairy took me to Hobby Lobby when Lowe's ran out of what I had been using. I bought a couple of small 2'x4' XPS sheets for filling voids then went to Home Depot and all they had was the pink stuff in 4'x8'. The Hobby Lobby "XPS" was much...

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    My kayak is almost done. Lots of lessons learned! I will do whatever I must to get the 2" foam next time. Sticking together all that 3/4" stuff was time consuming, less structurally sound, and upped the cost from using 5 times the amount of glue. Glue: 3M Super 77 works well if you stack on a lot of weight and give it a good cure, 3M Super 90 melts XPS. I also discovered there are many types of foam labeled "XPS" and they have very different properties. I discovered this 3/4 of the way through my project when the good idea fairy took me to Hobby Lobby when Lowe's ran out of what I had been using. I bought a couple of small 2'x4' XPS sheets for filling voids then went to Home Depot and all they had was the pink stuff in 4'x8'. The Hobby Lobby "XPS" was much like the cheap gas station styrofoam ice chests - very flimsy and unusable. The pink foam I like much better than the white stuff from Lowe's and I wish I had found it before I started. It is more densely packed than the Lowe's stuff and easier to shape/cut/sand. The Lowe's XPS falls somewhere between the pink stuff and the cheap Hobby Lobby styrofoam. I'm positive my boat will work fine, but I went to great lengths to ensure it would be rigid - steps I think I could have avoided by using 2" pink stuff, or even 1" pink stuff. I ended up putting a 1/4" plywood deck a couple layers down and a few stringers across joints and around the cockpit. I also glued in a 1" x 1/2" x 8' oak stringer centered in the hull to eliminate flex. I had to because using the 3/4" foam really hurt the structural integrity of the boat. It is very solid now, but additional weight was the sacrifice. It should come in at just under 40 lbs when it is done. For sealant I opted for epoxy garage floor paint. It was on sale for $28.50 and they tinted it green for me. While shaping the boat with the surform I ended up removing many of my bamboo skewers. I had thought about putting them back in when the shaping was done but now I am thinking I won't need them. If it comes apart in the surf I will put them back in on the next boat. :) I plan to get her in the lake this week to check the glide and stability and set my seat location. Once I get the seat where I need it and get the bugs worked out we are headed for the surf. I will post pics when I launch her. Thanks again for the great instructable. I plan to build many of these. Update with photos coming soon. Be safe

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  •  Sawfish, an unsinkable, lightweight, foam kayak (23 lbs). Free DIY kayak plans, the hardware store boat

    I sold my kayak a few years ago, then I moved about 7 months ago to a place not 10 minutes from a big lake. Even used kayaks are so expensive and I really want one so I can get out in that lake and fish. This popped up on a day kayak google search. I'm so glad I found this. I used to build surfboards in the 80s, spent the last 7 years building prosthetic limbs - this is right up my alley! Thank you so much for this! I started construction today. It is going to be slow since I live in Texas and could only get 3/4" XPS.

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