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Worked some this weekend and tonight. The top covers and bulkheads are done. I have to locate the support brackets and screw them in. After that I will be back to epoxy and putting on the inside glass. It is like a jugsaw puzzel trying to plan the first coat of epoxy, the fillet and the...

Had the day off so I did some work. The structure is complete for one end. I need to drill the hole for the plate and do the glue up. I made a substructure and I want it strong. The bulkhead is also a double ply. The top plate has a good fit but needs a little pressure during glue up.

Did some filleting and sealing last weekend to get use to the epoxy. It has been a few years since I did much with any quantity. The plastic spoon makes a nice fillet, thanks Chuck. I used 4 oz epoxy with equal parts Aerosil and wood flour (home made). A little rough but sands well. I am...

I made the gussets with patterns and a pattern bit in router table. Doublesided tape held the parts together and I nailed on the pattern. The shapes we rough cut on the bandsaw before final trim. They turned out nice and uniform. The material for the patterns is UHMW, polyethylene, that I...

I am two months in and at around $220. Laun is $11 per at Lowe's, Pine was $6 per 1x4x12, search for some clear stuff, 4 would make the steams, ribs and double rub strips. The epoxy and glass is the real cost. I went to US Composites and paid $160 for 1 gal resin (3:1), 5 yds of 60" 6oz...

Some progress made, I scarfed the bottom joints with a large center peice with short end peices. It was a real pain to scarf and I would recommend to plance the joint as much as you can before starting the sanding. I did use a 50 and 80 grit but it still took a lot of work. I now have a...

REI.com has a rudder kit for $120 that should just bolt on. If you think that is in the ball park I would give it a look. http://www.rei.com/product/786424

Have you used McMasterCarr for supplies? I use them at work for things like bolts, plastic, springs and bushings. They have several reostats that look like they would work. Must orders arrive next day. I did a quick search of Kayak rudder and several came up, including directions for...

The boat is now ready for the bottom. My kids are too young to help much, they vacuumed the floor today, but as you can see, they're ready to go. :) I am building it to make memories with them and hope to make another when they can really help. :D To get the wood home inside my car I had...

I was able to get the sides to smoothed out and only mislocated one rib but it was during dry fit. I will fill the holes later when I fillet. Capping the plywood with the rub rail did not turn out flush all the way. The glue foamed and covered the mismatch. I had to make a clearance cut for...

Here is the set up to use a router on the stems. I used a 1/2" bit set at the final depth. Then I start at the final line for the notch then work my way towards the end. After the first cut I feed the wood in the opposite direction to match the bit rotation. The bit will pull the wood...

Made some progress but the mistake I made with the stems is biting me in the butt. I made it 90 degrees off on the first cut and added a piece to make it tall. The extra glue area would help and it does, hold the nose in tight and mess with the angles for the ribs. It looks like I will have...

In the first two weeks I already made a some mistakes but I have figured out work arounds. The plan also changed and the finish will now be paint to hide the fore mentioned issues. The wife justs wants to know how long and where is it going, so I had some time today to work on it. The stems...

This is my first post but after reading this site for the last 2 months I wanted to post my build, as it is about 12 years in the making. I first started in CA in '97 in my in-laws garage. It was together and filleted when we moved and it went to storage in my mothers house. After 7 more...