We’ve Worked Hard to Make it Easy
The 24 Hour Kayak is designed to be built by first time boat builders and novice woodworkers with limited time, resources and acquired skills.
novice woodworkers
first time boatbuilders
youth groups and not-for-profits
high school shop classes
adult/child teams
Hour by hour instructions are available online to help new builders through the process. It’s our firm hope that anybody with some patience and basic skills will be able to follow along and successfully build this kayak.
Skills Required versus Skills Acquired
Wood workers who are familiar with a standard selection of shop tools will find that building the 24 Hour Kayak is well within their already acquired range of skills. Despite her flowing lines, there are no complex angles, joins, or difficult measurements required.
For those who haven’t worked with wood before your greatest asset will be patience and the good sense to slow down if something feels unfamiliar and practice a cut or trim pass on a piece of scrap material before trying it on the boat.
To Build This Boat You Will Need To:
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- Transfer dimensions accurately to plywood panels
- Rough cut curved sections of plywood panels
- Accurately cut parts from 6mm plywood
- Rip a piece of lumber into 1″ x .75″ strips with a 12 degree angle on one side
- Bevel a short section of the chine-logs
- Use a power drill and driver to attach plywood panels to the frame
- Trim panels flush to the frame after installation
- Accurately glue coaming parts and fittings to the hull
- Prepare hull for finish, and apply finish coatings
Builders Will Need to Use A Combination of the Following Tools and Materials
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- A table saw, or circular saw with width guide to cut the chine logs.
- A jig saw, or patience with a hand saw, to cut curved sections from plywood sheets.
- A laminate trimmer, or patience to hand trim the hull and deck panels to their final shape.
- Driver and drill set to assemble all the parts.
- Portable belt sander, or power plane, or block plane, to bevel the forward portion of the deck chine-logs.
- Construction adhesive.
- Random orbit sander, or finish sander, or patience to use sanding blocks to prep for the finish treatment.
- Exterior epoxy primer and paint, or varnish.
As you can tell by these lists, there is no single one way of doing things. Some builders may choose to use hand tools exclusively, and others will have a fully outfitted shop complete with floor tools and a finishing booth. Suffice it to say that you should have a basic understanding of the safety implications of each tool you choose to use, and the good sense to slow down and think through each step.
An Important Note
Using a Laminate Trimmer to Safely Shape Panels
The ONE thing that makes building the 24 Hour Kayak much quicker and precise is the use of a laminate trimmer to trim the bottom and side panels to their final dimensions. The angles work for all sections EXCEPT the portions of the deck forward and adjacent to the cockpit opening. The angles are NOT square and even experienced craftsmen could find themselves in trouble with an errant blade.
When trimming the deck panel DO NOT be tempted to run the trimmer forward of the aft sections of the cockpit!
Be safe. Please. Use a jig saw or back saw to trim panels where it isn’t possible for the laminate trimmer to run flush on its base. You can always finish up afterward with a plane or belt sander.
Building the 24 Hour Kayak – A Simple Plywood Boat
Introduction | Tools and Space | Materials | Ordering Plans| Overview – Build Sequence