Building the North Alaska Retrieval Kayak (modified by D. Mace)
Materials required
pine boards for deck and hull stringers
ash or white oak wood (preferably freshly harvested and still fairly green) for ribs
spruce, pine or other softwood for deck pieces, stem and stern
synthetic thread for binding frame pieces
sewing needles (both curved and straight) and sewing awl
canvas (or other covering for kayak "skin")
waterproofing for kayak skin (waterproof stain with fungi and ultra violet inhibitors)
tung oil (or shellac or varnish) to protect wooden frame
Tools required
square and adjustable bevel square
tape measure
saw horses (2 per kayak)
Lots! of clamps
crosscut saw (japanese crosscut saw is very useful also)
hand plane(s)
crooked knife - optional (another workshop project being to make a crooked knife)
drill and bits
wood chisels and sharpening stone(s)
table saw to rip wood into sized lengths and widths (onsite or available for pre-cutting)
steam kettle and steamer set up
gloves to handle hot wood
Kayak building time(s) for the North Alaska Retrieval Kayak
Building time for seasoned woodworkers (motivated)
Building time for motivated people able to use common woodworking tools (square, saw, drill, chisel, measure)
Building time for total beginners
motivated
non-motivated
Work schedule (steps of the process)
Send course outline and intro to participants by email and invite them to view a web-available powerpoint describing tools and process in order to familiarize themselves with the process
Set up sawhorses
Introduction to selection of appropriate wood for the longitudinal frame pieces (grain, curve, knots, weight, type)
Introduction to basics of measuring, tools involved, offsets in boat building, base line and symmetry.
Choose and set up first two stringers with a temporary brace to develop the curve and appropriate width of the deck
Introduction to the use of bevel and right angle squares, plane and crosscut saw
Measure, layout, cut and join stem and stern pieces
Use crosscut saw to create a joining surface on both ends of the kayak's deck stringers
Join the deck stringers to the stem and stern pieces
Introduction to the use of drill and wood chisels
Mark deck stringers for placement of deck framing
Choose, measure and cut deck framing pieces and connect them to the deck stringers
Flip the deck over and mark placement of ribs on underside of deck stringers
Drill and chisel mortises for eventual ribs
Brace the keel piece in its final position and attach it to the stem and stern pieces with a tailored cut on each end
Introduction to the process and principles of steaming wood
Prepare ribs for steaming and begin the fitting process, bending and clamping the ribs, one at a time, to the deck stringers
Cut ribs to perfect length as they dry for insertion into mortises and install them sequentially from the middle of the kayak toward the ends
Attach the ribs to the deck stringers after sighting down the entire installed set of ribs to ensure symmetry and gradual curves
Prepare further hull stringers in pairs,
Attach all stringers to ribs, stem and stern
Steam and bend the cockpit ring, join with scarf joint, drill holes for "skin" around ring
Attach the cockpit ring to the frame with midway support pieces
Finish all frame pieces with Tung oil (or marine varnish) and allow to dry
Cover the finished frame with the canvas "skin", tighten and sew, waterproof (two coats)
Build a double bladed paddle for the kayak
Time to head out on the water (choose a shallow shoreline with calm water and little wind for the first launch)
Don't forget your life vest
Pat built this North Alaska Retrieval Kayak during a workshop in Gaspesie, Quebec, Canada
Pat's Retrieval Kayak seen in profile
Pat's Kayak seen from the bottom