Building an Outer Island

Building the Hull

Before I could start adding wood strips for the hull I needed to mill them from the 3/4" planks I purchased. The 1/4" wide strips were cut on the tablesaw then run through a surface planer to make sure that they were all the same thickness. Then they were brought over to my router table so that I could put on a bead and cove.

Beginning of the hull with first strip attached.

After adding that first strip I made a couple of strips that were 1/2" cedar and 1/2" pine to use as accent strips along the sheer line. I had to make a long 20' jig so that I could glue the strips together first. I added two of these strips on each side for the accent.

Accent strips added. Those short strips on the forms are there to keep the forms line

Next, I just started working my way up the hull on each side adding strips. Each strip is glued to the one below it, and although it's hard to see from the pictures, stapled to the forms. The staples are necessary to keep the strip in place until the glue dries.

Adding strips. Note the thin strip ready to be attached along the keel line

After adding several strips along the sides, I added the strip which runs down the keel line. These were half wide strips which had a "rolling" bevel on one side. Once these strips were added I started to alternate working down from the keel and up from the sides. That gray stuff on the forms in the picture above is duct tape. It's to prevent the strips from being glued to the form. I used a lot of duct tape for this project.

The hull is getting close to being completely covered.

The last few strips were a bit tricky because they had to be carved to fit the small openings but all the pieces eventually went into place.

The last strip is in! In case you were wondering, that window just above the kayak is how the boat will get outside..., and yes, I already measured it.

After the last strip on the hull I removed most of the staples and used a plane and cabinet scrapers to "fair" the hull. There were lots of gaps that I filled in using slivers of wood and glue. Then I sanded, filled in the small gaps with a concoction of epoxy resin and sawdust, and then sanded some more. Now it's onto to building the deck. Click on the link below.

Building an Outer Island Kayak