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Construction

Posted By Dan Caouette

Layup Options

Standard | Performance | Performance Carbon | Expedition | Expedition Kevlar | SOF

The term “composite” means combining different products together into one structural unit.  The addition of the two fiberglass/Kevlar/carbon fiber skins to a wooden core create a structure similar to an I-beam. The wood provides light weight, stiffness and beauty, while the fiberglass and/or other fabrics absorbs virtually all of the loading.   They are stiffer and lighter than comparable fiberglass hulls, and slightly stiffer than prepreg epoxy hulls. The difference is due to the low density of wood (a third of fiberglass/polyester). Thus the hull can be thicker, which is the most efficient way to increase stiffness. Stiffness means strength and durability – and stiffness plus low weight means speed, acceleration and superior maneuvering. This makes them a great value even though many hours of labor are required to make a wood-composite kayak or canoe and the high-tech materials are expensive.

These are our standard composite layups. They can be modified as needed to suit your unique project.


Standard

The standard for all of our wood-core kayaks.  A good compromise of stiffness, weight, durability and cost.

– Solid Wood Core: 3/16″ Thick solid wood core. S&G: 4mm Okoume plywood
– 4oz Woven E-glass inside and out
– Extra reinforcing layers of glass under the waterline, in wear areas and other structural areas
– Unidirectional carbon fiber strengthening beams as needed on deck and/or hull
– Hand laid with Super Sap bio-derived epoxy
– Exterior Finish: Urethane clear coats and/or paint
– Interior Finish: Super Sap CLR Epoxy

Typical Weight (Kayak) = 36 pounds


Performance

– Solid Wood Core: Hull = 3/16″/ Deck = 1/8″ thick. S&G: 3mm Okoume plywood
– 3oz Tightweave Woven S-2 ‘glass inside and out
– Extra reinforcing layers of glass under the waterline, in wear areas and other structural areas
– Unidirectional carbon fiber strengthening beams as needed on deck and/or hull
– Hand laid with Super Sap bio-derived epoxy
– Exterior Finish: Urethane clear coats and/or paint
– Interior Finish: Super Sap CLR Epoxy

Typical Weight (Kayak) = 28-30 pounds


Performance Carbon

– Solid Wood Core: Hull = 3/16″/ Deck = 1/8″ thick.   S&G: 3mm Okoume plywood
– Exterior: 5oz Woven carbon fiber on exterior of hull and/or deck
– Interior: 3oz Tightweave Woven S-2 ‘glass
– Extra reinforcing layers of glass under the waterline, in wear areas and other structural areas
– Unidirectional carbon fiber strengthening beams as needed on deck and/or hull
– Vacuum-bagged with Super Sap bio-derived epoxy.
– Exterior Finish: Urethane clear coats and/or paint
– Interior Finish: Super Sap CLR Epoxy

Typical Weight (Kayak) = 30 pounds


Expedition

– Solid Wood Core: 3/16″ Thick solid wood core. S&G: 4mm Okoume plywood
– 3oz Woven S-2 ‘glass inside and out. Double laminations.
– Extra reinforcing layers of glass under the waterline, in wear areas and other structural areas
– Unidirectional carbon fiber strengthening beams as needed on deck and/or hull
– Hand laid with Super Sap bio-derived epoxy
– Exterior Finish: Deck: Urethane clear coats and/or paint.  Hull: Epoxy/silicone or graphite
– Interior Finish: Super Sap CLR Epoxy

Typical Weight (Kayak) = 40 pounds


Expedition Kevlar

– Solid Wood Core: 3/16″ Thick solid wood core. S&G: 4mm Okoume plywood
– Hull Exterior: 4oz Kevlar-49 with layer of 3oz Woven S-2 ‘glass inside and out.
– Interior: 4oz Kevlar-49
– OPTION: Carbon/Kevlar can be substituted for Kevlar at additional cost
– Extra reinforcing layers of S-2 glass under the waterline, in wear areas and other structural areas
– Unidirectional carbon fiber strengthening beams as needed on deck and/or hull
– Hand laid with Super Sap bio-derived epoxy
– Exterior Finish: Deck: Urethane clear coats and/or paint.  Hull: Epoxy/silicone or graphite
– Interior Finish: Super Sap CLR Epoxy

Typical Weight (Kayak) = 40 pounds


SOF

– Solid wood and plywood frame
– Heat-shrunk Dacron fabric base layer
– 3oz Tight-weave Fiberglass Structural Layer
– Additional laminations at swear locations (stems)
– Hand laid with Super Sap CLR bio-derived epoxy
– Finish: Can be left slightly translucent or painted

Typical Weight (Kayak) = 30 pounds

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High performance kayaks, canoes and other small boats. Crafted individually in the USA.