Opening the box. Everything but the epoxy was packaged in an eight foot box. The completed kayak will be seventeen foot long.
Laying out the pieces. Most pieces are 4mm Mahogany plywood.
More pieces.
The pieces are layed to be butt joined.
Prepare for epoxy.
Layout of fiberglass and mylar film for each joint.
Cut fiberglass and mylar.
Cut fiberglass and mylar.
Bricks are placed on the plywood and the joint to make sure nothing moves and everything is even.
Close-up of joint with epoxy, fiberglass and mylar film.
Add 1x4 and brick to flatten seam.
All 7 seams setup for curing. This represents on side of the boat. The seams will also be joined for the other side.
Finished seam with mylar
Finished seam with mylar removed
Excess epoxy is scraped off.
Completed side.
Completed seams.
Clean debris before joining second side.
Preparing epoxy. The epoxy consists of a resin and a hardener. The jugs of epoxy have "ketchup" pumps. The ratio is 2 parts resin to 1 part hardiner. The hardener pump has a restrictor to limit it to a half pump. One pump from the resin and the hardener is about 1.5oz of epoxy.
Mixing the epoxy.