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Bryan's Kayak

** update ** Kayak Maiden Voyage

Have I mentioned, I love my shop? It seems there's always a project underway, many of which I don't bother to document.


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We Begin

2005.09.18

But this project of salvaging Bryan's Kayak is one I forgot to start documenting from day one and wish I would have. It's a spectacular 18' Kayak that Bryan has asked me to help Refurbish. With Gorgeous lines, it just screams fast, even as it languishes in the shop, waiting patiently for the touch of water passing over its thin skin.

It's been sitting outside in the weather for about 8 yrs and for some reason, while the inside epoxy, glass and fillet work is superb, the exterior work has been severely deteriorated due to UV damage. So, there was a lot of water penetration and even some patching that needed to be done. The Exterior glass pulled off almost without any damage to the wood underneath, which told us it had a pretty poor bond.

Plus, there was a removable skeg that we have smoothed that structure out and will be glassing over it.


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So, After a little filler in the places where we dug out wet wood and a flat out patch or six, we're almost ready to saturate the wood with epoxy and lay the glass back down. The dark splotches are caused by using Teak Wood flour for filler, which turns the epoxy very dark. Since this boat will be painted, I used the Teak Flour since it was already at hand.


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My worthy assistant is also helping with the new coaming we're building to replace the current rotted one. This one will be epoxy saturated and glassed in, so there won't be any possibility of rot. In addition to the joy of the project, I get to spend a lot of quality time with my buddy Bryan. Always good to spend time with this gentle soul.


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Re-glassing the sides

2005.11.30

I know, I know, it still looks like a boat being worked on. But, what you see here represents about 100 man hrs of sanding, filling, re-sanding and refilling and finally some glass.


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2005.12.23

All is nearly finished and ready for paint. Final smoothing coats of epoxy have been added. Now, awaiting cockpit coaming, seat and foot rest installation. And then finally, prep and paint.


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2005.12.30

Most of the work is done now. In between every step, sanding, sanding and more sanding. I've blown out and vacummed more dust than I care to remember. Everything is Dusty, the kids won't hug me because I'm pokey. But the Kayak is looking good.


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2006.01.03

Prepping for the Coaming assembly here.


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2006.01.10

A nice little rub rail to protect the hull deck joint from the paddles and other abusive creatures.


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2006.01.22

Getting very close to painting time, now. Yesterday, we put the last layer of the coaming on and today I removed and sanded.


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2006.01.22

Over the coming week, I'll do some more sanding and a final coat of epoxy for the coaming and cockpit seat and we are ready to flip the boat to paint.


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2006.01.28

Painting Begins


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2006.01.28

Painting Begins


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2006.02.04

Bryan's Brother in law, James started this project and until now, Bryan had not told James what he was doing. Today, as a surprise, Bryan told James he needed him for an hour and just brought him over here. James was delighted to see the progress we made and even chipped in on some sanding and painting.


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2006.02.14

Finished painting the deck and just added last coat to the cockpit. All that's left now, is varnishing the seat.


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