Cheap Plywood Kayak Project

They needed a fast, inexpensive, roomy kayak for travel. The choice fell on a plywood kayak using "sew-and-glue" technology.

Step 1: Planning

Drawings of the "Chesapeake 17" and "Shearwater-17" project were found on the Internet. Approximately the same as in the photo. A little bit to adjust for yourself. I narrowed it down a little and raised the "deck", added a couple of bends. (Unfortunately the drawing was lost during construction). You can start building.

Step 2: Preparation Tools

Find a spot large enough for a kayak. We collect the slipway (large table)
The tool I am using:
- jigsaw
- Sander
- knife

-scissors

- clamps

- brushes

- syringes for resin

- pliers

- respirator

- rulers

- miscellaneous as needed

Step 3: Preparation Materials

We buy 4 sheets of 4mm plywood. Epoxy resin 3 kg, 2 slats

Step 4: Preparation

We mark the plywood (sheet dimensions 1525 * 1525mm) according to the width of the parts in the drawing and saw it. We "sharpen" the cut pieces and peel them with epoxy resin.

Step 5: Transferring a Drawing

Transfer drawings to sewn plywood

Step 6: Cut

Sawing along the drawn contours.Sawing along the outlined contours.To make both sides even, you need to fix two identical parts with clamps.

Step 7: Fixing the "deck"

To attach the top of the kayak, glue the prepared slats to the cut-out sides

Step 8: We Sew

We sew the resulting parts with wire and see how beautiful it turns out

Step 9:

Installation of bulkheads and alignment / gluing of slats.In the project from the Internet there was a drawing of the bulkheads, but since I changed the kayak for myself, they no longer fit. I had to take cardboard and cut it in place. Transferring the cardboard stencil to the plywood

Step 10: Filling Joints

Аill the joints with a mixture of resin and wood flour

Step 11: Stabilization

To stabilize the bottom, I put 1 layer
Fiberglass Evenly spread epoxy with soft spatula
And also the future cockpit (the place where the person sits) I cover with fiberglass with epoxy resin

Step 12: Deck

It's deck time . I fit the plywood to size and fasten it with self-tapping screws

Step 13: Fiberglassing Deck

Cover the deck with fiberglass and sprinkle it with epoxy, spreading it evenly.If the resin is too thick, you can warm it up with a construction hairdryer

Step 14: Details

Cut out hatches and cockpit, give shape to hatches. I made a model of hatches from paper.transferred to plywood

Step 15: Fiberglass in All

We cover the deck and bottom of the kayak with two more layers of epoxy resin fiberglass.

Step 16: Priming and Painting

After the epoxy has hardened, proceed to painting. First applied the primer, and then the paint

Step 17: Sundry

I add the fastening of the hatches, and the trunk from the rope

Step 18: Testing

Testing

Step 19: Outriggers

If your kayak is not stable, do outriggers

Step 20: Outrigger Construction

From the remnants of plywood or from a new sheet, a crossbar and 2 mini-kayaks are glued together, everything is fastened together. Cover with epoxy fiberglass and paint (like a kayak)