E A S T E R N H O R I Z O N K A Y A K

Episode 58 - Working out the many tasks ahead

2012-01-28T11:50:00.002+11:00

The kayak with its 5 hatch covers sitting on deck.

Bewdy - it fits.

With the hatchcovers sitting on their hatches the deck is very flush.

Additional clutter yet to be incorporated includes a 40 year old black rimmed Suunto yacht racing compass, multiple black kevlar deck fittings and a black cord deck line.

A clear fabric sail may be fitted at some time in the future.

Recessed skeg slider mechanism.

The cockpit coaming is carbon fibre.

The retractable skeg popping through the kevlar keel strip.

I had originally intended to install a skeg / rudder system but it proved too bulky inside the compartment. Lawrence's past experience with them was that they were prone to failure so better to simply have a more robust up and down skeg.

The skeg fin should be black, however. Will change that.

The hatch to the most rear compartment provides access to the skeg box.

There's a second larger hatch forward of this which accommodates larger items ~ sleeping bag and tent.

I am yet to fabricate the water seals to the hatch covers and their corrersponding carbon fibre lips.

Stern detail of whale bone and recessed shell.

Momentoes of two special places visited by kayak.

Episode 57 - Lawrence of the south coast

2012-01-27T21:30:00.007+11:00

For the last 3 months the kayak has been in the workshop of Lawrence Geoghegan.
Lawrence has installed the skeg, the carbon fibre cockpit coaming, the bulkheads, the kevlar keel strip and undertaken the bonding of the hull and deck.

The Nadgee workshop.

Keen observers may recognise the middle boat as one that has seen more coastlines than most.

Lawrence finishing off some of his robust workmanship - in this case the kevlar keel strip.

Pausing from the road journey back up the coast to stretch legs, stand back and look at the almost completed kayak.

It's a beautiful elevation.

The Greenlanders were on to something when they developed this design of kayak in the 1600's.

Above the kayak is Montague Island on the eastern horizon.

The immeasurable

2011-12-14T19:58:00.002+11:00

"Time that is moved by little fidget wheels
Is not my time, the flood that does not flow."

The timber kayak has been patiently waiting to one side while Lawrence clears his tables of production kayaks.

The focus will return to the timber kayak in a couple of weeks.

(Quote from Five Bells - Kenneth Slessor)

Episode 56 - Hatch portal lip

2011-10-20T20:31:00.001+11:00

The beginnings of what will be a clear coat carbon supporting rim for a flush cut hatch.

Episode 55 - Mounting the retractable skeg rudder system

2011-10-19T19:39:00.000+11:00

Against good advice I have decided to proceed with the installation of the retractable skeg / rudder system. The main concern with this device is that a small mechanism that engages with the foil to operate it as a rudder has been known to fail in previous instances of its use. Lawrie has had to contend with some other design deficiencies in the system's housing box and flanges but I'm pleased to see from the image above that these hurdles have been overcome. Thanks Lawrie!

Episode 54 - Hatch portals

2011-10-19T19:06:00.002+11:00

"Ta da" - Lawrie has deftly taken the sharp blade to the deck.

The five hatch covers.

Episode 53 - Lawrence's workshop

2011-10-19T06:49:00.002+11:00

The kayak is now in the very good hands of Lawrence Geoghegan at Nadgee Kayaks.

Lawrence continues to be a local kayak builder - which is fortunate if we are to have a kayaking culture that is distinctive and relevant to us along the east coast.

It is into Lawrence's experienced hands that I have placed my kayak to have many of its remaining tasks completed.

Setting out the dimensions for the cutting of the deck hatches.

Episode 52 - East coast homeland

2011-10-17T14:03:00.003+11:00

A quick sketch to describe where the principle materials of this kayak have been sourced and the places where they have been constructed.

East coast materials:

Spotted gum from the hills behind Coffs Harbour.

Cowry shells from Valla Beach.

Australian Red Cedar from a south-facing slope near Gloucester.

Turban shell from Little Bay, Sydney.

Humpback whale bone from east coast of Maria Island, Tasmania.

Huon Pine from south-eastern Tasmania.

East coast worksites:

Valla Beach

Sydney - Bondi, Cooks River and Port Jackson

Double Creek, Bargo.

Travelling through a south-east coast forest in the final stage of this kayak's genesis.

Episode 51 - Surface finishing continued

2011-10-13T07:00:00.000+11:00

Last night.

Tony applying a top coat.

This morning.

Still a few blemishes to work on.

Episode 50 - Surface finish

2011-10-12T13:49:00.004+11:00

Life is busy and my skills are limited so in order to finish the kayak off before the whales are travelling north once again I've decided to contract a specialist kayak maker to complete all of the many detailed and more difficult aspects of this kayak - the carbon fibre cockpit coaming, the flush-mounted hatches, installing the retractable skeg / rudder system, installing the bulkheads, bonding the hull and deck together ... and on the list goes.

But before sending the kayak out the door a friend (thanks Tony) and I have been sanding and re-coating the surfaces multiple times this week to achieve a good finish.

This was the kayak as of yesterday morning with the deck resting on the hull (not yet bonded together). It's great that the kayak will be completed by a skilled set of hands and slipped in the water within a few weeks, I hope.

Episode 49 - Seat prototype

2011-10-08T13:40:00.002+11:00

This is a prototype seat shell that I've fabricated using the offcuts of Australian Red Cedar and Huon Pine.

It's based on a rowing scull seat and, as such, it looks to be completely impractical for long-distance kayaking where lots of cushioning surface area is usually considered to be the best solution ... but, having cut a finger off in the process, I'm going to press on and give it a go anyway. It's yet to have an impact-resisting layer of Mini-cel foam laid onto it which should improve its performance.

It's certainly comfortable to sit on as it was tailor made to fit.

Not pictured is the back support and hip braces that I've also made using the same timber species. All of the timber surfaces will be resin-coated.

If this seat does not prove to be a good solution then I'll be carving a new one from a block of Mini-cel foam somewhere further into the future.

Episode 48 - Ooops

2011-08-13T16:05:00.000+10:00

I epoxied the seat profiles into three sections and I was just about to give them a quick sanding when I made a bad decison to adjust a setting on the belt sander while it was operating, got a finger caught between the "Very Coarse" grade sand paper and its protective guard, and then took an unscheduled trip to hospital while the wife passed out.

Warning! Really gorey image below ...

The outcome is that the naughty finger on my right hand is now 15mm shorter.

A minor setback, you could say ...

Monty Python and the Holy Grail.

Episode 47 - Shaping a bespoke seat (continued)

2011-08-07T15:45:00.001+10:00

My kind neighbour, Brian, has lent me a hand by cutting out the profiles for the kayak seat with his bandsaw.

Note that he has all of his original fingers.

Pictured above is the rough shape of the seat.

The two pale strips are of huon pine and, being stronger than the Aust Red Cedar, will provide the structural stiffness to the laminated seat. The next step is to resin all of these profiled strips together with pressure clamps.

The other pieces visible above are the laminated back band and cheek plates.

Final distraction before completing the kayak ...

2011-07-03T20:33:00.005+10:00

This journey of building a kayak has experienced a few enjoyable diversions.
Such as this one to construct a cubby house ...

I've recycled some of the kayak's offcuts into this cubby house including the "strong-back" from the kayak's formwork and sections of spotted gum - from the same batch used to make the kayak's outer stems.

The cubby house is constructed with the ruins of an old brick bbq as a footing.

The mid-level will serve as a native orchid house.

Felix fine tuning the lifting pulley.

Materials used:

Blackbutt posts

Spotted gum roof framing

Spotted gum floor battens

Recycled hardwood floor joists (species unknown)

Tasmanian Oak dowels

Australian white cedar soffit

Galvanized mini-orb

Clear polycarbonate

A great place to hang a native orchid or six.

Other kayaking momentoes find their place too - abalone shells from multiple east-coast expeditions, hump whales bones (also used in the kayak and its paddles), and various coastal dwelling native orchids.

With the cubby house now out of the way it's time to get back on to building that kayak!

Episode 46 - Shaping a bespoke seat

2011-06-15T18:30:00.004+10:00

A sketch of the seat, backrest and cheek plates.

The bespoke shape to (half of) the seat was carved from a high density foam ...

The seat shape was then sliced into strip templates ...

The shapes of each of these foam strip templates will next be transferred to wood strips which will then be cut to shape, laminated together and sanded fair.

Episode 45 - Bulkheads (test fitting)

2011-05-14T16:32:00.005+10:00

One of the un-glassed bulkheads.

Initial set-out of the bulkheads within the hull.

There is a day compartment and two compartments in each of the fore and aft sections - see earlier posts for the reasons why.

"Is this where I get to sit?"

(The incongruous-looking thing in the aft compartment is the skeg rudder system)

"When I'm bigger I'll sit here".

The bulkheads will be set out to correspond with the volume of the things that will be stowed within their compartments - such as my sleeping bag.

I don't yet know how I will bond the bulkheads to the hull and deck. I would like to use a flexible /compressive organic material. If Xanthorrhoea resin did not set rock hard then it would be most appropriate.

The bow.

Episode 44 - Bulkheads (laminating)

2011-05-14T16:16:00.002+10:00

A sheet of 0.6mm Australian red cedar was carefully cut and then resin-laminated onto each side of the marine-grade Australian white cedar.

Episode 43 - Bulkheads (prototype testing)

2011-05-08T21:44:00.003+10:00

There are many different approaches to forming the bulkheads to a kayak.

I'm initially testing a method that uses 5mm marine grade plywood that will be held in place with a flexible channel seam - to absord at least some of the impact of a future unplanned landing upon a rock garden.

Firstly, the old station forms that had been sitting out in the garden during three months of recent rain were retrieved to serve as templates for the bulkheads.

Kayak boy #2 tracing the template.

We are using 5mm Australian white cedar marine grade ply for the bulkheads

I will laminate an additional skin of Australian Red Cedar on to both faces of each bulkhead at a latter stage.

The bulkheads sitting loosely within the hull.

The very observant will see that there is a non-typical additional compartment towards the stern.

I'm likely to also include an additonal bulkead within the bow (which will also serve to better distribute the force from the sail rig which will eventually be fitted to the deck immediately above it). Additional compartments mean additional weight and more chances of water ingress through the additional hatches. My reasoning for going to this trouble (and risk) is that this kayak is 6.1m in length so to be able to access the furthest extents of its storage compartments fully - and without having to unload an entire compartment to access that desperately needed item jammed up its narrow end - it seems to make some sense to have multiple compartments both fore and aft of the cockpit. If the kayak were to be stoved-in at some unfortunate location then these extra bulkheads may well prove their worth.

And in terms of constructability, having access through hatch openings that are close to the bow and stern will be very useful for ensuring that the internal sheerline seam is well bonded to the deck and hull.

Episode 42 - Kayak stand

2011-05-01T13:44:00.006+10:00

Back at Ian's boatshed we spent a day fabricating a kayak stand using the offcuts of Aust red cedar and spotted gum.

The 1:5 model of the kayak and its stand is on the left. The actual kayak is on the right.

And here it is with a lick of tung oil in the Sydney autumn sunshine.

The paddles are supported mid-way up the stand

The kayak stand has four tension connections that allow it to be dis-assembled and transported.

I've used cowrey shells that I found along the mid-north coast as toggles.

The "toes" are of spotted gum.

The "tree nails" are of Tasmanian oak.

The frame is Australian red cedar.

The stand serves as a drying rack for wet gear.

A kayak, two paddles and a kayak stand formed out of two beams of Aust red cedar, a plank of Huon Pine, a few sticks of Spotted Gum, a dowel of Tasmanian oak, two pieces of hump back whale bone and four Cowrey shells.

In the backgound, a young garden of indigeneous east Australians : grevilleas, banksia serrata, banksia ericifolia, banksia seminuda, banksia integrifolia, angophora coststa, callistemons, and a handful of dendrobrium orchids.

Episode 41 - Glassing the interior

2011-04-26T16:55:00.007+10:00

Travelling with the kayak through a mid-north coast woodland towards a few days work in a macadamia shed ...

The kayak's exterior has a robust sepia- coloured finish to it but the interior is still raw.

Not unlike the macadamia nuts growing all around this landscape.

The interior surfaces of the deck and hull were sanded in the open air between rows of macadamia trees.

The fibreglassing of the interior surfaces took place within the shelter of the farm's work shed.

I've been looking for a way to reference the geology of Australia's east coast and here's my solution ...

The sand is scattered by small hands on to wet epoxy.

The mask of tape is peeled off.

A non-slip surface to the cockpit entry.

The chevron pattern is derived from elements of traditional Koori (South Eastern Aboriginal) line work.

Jonathon Jones incorporates chevrons in his artwork to link ancient indigenous traditions with contemporary technology.

Jonathan Jones

"untitled (the tyranny of distance)" 2008, Sydney,Australia.

Episode 40 - Farewell to the formwork.

2011-02-24T13:49:00.002+11:00

Yesterday evening the internal formwork was removed from the deck.

With a few strategic severs of the strongback it came away easily.

It's quite a momentous moment in the evolution of the kayak - a bit like an insect shedding some part of its body.

This morning, for the first time in the construction process, I was able to sit within the cockpit.

I'm very relieved that my feet have plenty of space and that my upper thighs lock in sweetly with the deck profile.

Also for the first time I was able to check how the weight of the combined deck and hull is coming along.

At the moment it is weighing in at a delightful 17.5 kgs.

The surface finish is looking a little mottled (too many rums when we laid it) but some careful sanding and a second coat of resin will hopefully deliver a refined glassy surface.

Episode 39 - Glassing the deck

2011-02-17T23:19:00.022+11:00

The partially built kayak looking rather splendid back at the harbour's edge.

This evening's enjoyable task was to glass the deck.

But first the deck (and its supporting formwork) was removed from the hull and the deck then given a final once-over with a fine grit paper on the electric sander.

Then the almost ceremonial aspect of this phase of the works could proceed ... the deck was draped in its 4oz cloak of woven fibreglass.

The West System two-part resin was gently blended - being careful not to introduce air bubbles in to the mix.

A light nor-easter and the pleasant sound of waves was flowing through the boatshed as the resin went on

Bill and Tony carefully working their way along the deck. Helping the resin to find its way through the cloth and into the grain of the cedar.

From tree to sea.

A still moment to reflect on the transformation.

The next step is to fair the inside surface of the deck and then glass it and the inside of the hull (separately). Then there will be a lot of interesting work to fit the skeg / rudder system, foot rests, seat, cut out the hatches ... and on it goes ... before eventually bringing the hull and deck together.

Episode 38 - Cutting out the cockpit opening

2011-02-15T23:05:00.004+11:00

At various stages in this journey there are design decisions that need to be made that will affect the kayak's performance. One of these points was reached this evening in committing to a particular size and shape for the cockpit entry portal. There are a range of approaches available from the tight ocean style of portal to the key hole and open mouthed portals. I have chosen to maintain a generous opening to facilitate entry / exit and general maneuverability.

I drew up three slightly different sized templates for the cockpit entry and compared them with the cockpit portal on my old fibreglass Greenlander. I tried entering and exiting each of these paper templates. You can see that I tore the second template - it was too narrow for me.

Having established the template with the best fit I then used the cut out piece to trace the cockpit portal's shape onto the timber deck. I was very careful that the shape was accurately aligned with the deck's central axis.

And then an electric jigsaw made quick work of cutting out the portal.

This portal will subsequently be augmented with a carbon fibre coaming lip and integrated thigh braces.

Episode 37 - Deck and non-indigenous bits

2011-02-02T20:20:00.003+11:00

Tony lends a hand by assisting Kayak Boy #1 (Felix) to fair the deck.

And the Tasmanian pinot assists Tony.

One of the intentions with the construction of this kayak is to use local materials wherever possible. I've been fortunate in being able to source local timber and whale bone for the body of the kayak.

However there are some specific bits of additive kit that I have been unable to obtain locally ...

For example, I've been unable to find a locally made marine compass of high quality so I'm going to embed into the kayak's deck the compass shown here - it's a Suunto tactical marine compass made in Finland circa 1975. It's a beautifully robust compass of impeccable construction.

It's weathered condition will hopefully form a harmonious relationship with the wood of the deck.

Beneath the bonnet is a different creature ...

The second major component that I have chosen to source from over the distant horizon is this: It's a combined skeg rudder system from Kari-Tek.

Operated by hydraulic rams (rather than the wires found in all other operable rudder systems) this collection of components is absolutely beautifully engineered.

And, as far as I can establish, it is the only retractable skeg rudder system available for installing along the keel line of a kayak.

(It also costs a small fortune.)

This is the retractable blade when fully deployed and operable as a rudder.

When partially deployed the blade serves as a skeg.

I think that it's a great piece of design because it locates the skeg / rudder in a more effective position along the hull than the typical tail-end position which loses traction in larger seas. In this sense it has the benefits of the rudder used in racing skis. But it is better than that mechanism as it can be fully retracted. Presumably this design will find its way into racing skis before long.

The detraction from this design, however, is that the system's housing invades the internal territory of the kayak's available expedition storage space. Though, as it is a relatively slim device, I am hoping that the loss of space will be minor.

This is the toe-operated hydraulic steering mechanism.

The white acrylic "beam" is mounted to the underside of the deck and allows flexibility with the positioning of the toe plate along its length.

And this is the slider that hydraulically operates the raising and lowering of the blade.

(For the uninitiated, all of the tubes will be housed beneath the deck.) The slider box will be mounted into the deck's surface. A small piece of whale bone will cover the sliding block.

When I began this journey to make a kayak I had many aims. One of the expressed ones was to make a vessel that had its principle elements sourced exclusively from indigenous / local sources. Over this last summer I have read David Malouf's "A Spirit of Play" - which was delivered by the author in the Boyer Lectures - and refined my approach to local identity and the specifics of place.

Here is an important excerpt that has some relevance to me and my kayak:

They (Governor Phillip and members of the First Fleet) had come here expecting to find natives. They had an impeccable document that outlined how they should deal with them. They knew, either from previous experience or from their reading in Montaigne and Shakespeare and Rousseau, and from Defoe's 'Robinson Crusoe', what a native might be. And from Cook and Banks what these natives might be. But Bennelong was not expecting this meeting. He had no preparation for it but his own capacity to observe, open his imagination, and respond.

What he made of Phillip, the room he made in his world for Phillip's authority and for Phillip's house as a 'sacred site' (he insisted, for example, that his daughter be born in its grounds) speaks for an act of accommodation, of inclusiveness, that is an example to each one of us, and, considering all that followed, a shame to each one of us as well. But Bennelong, however weak he may have been in physical power, had behind him the strength of a culture that in being old had developed, in its long view of things, an extraordinary capacity to accept and adapt to change. It is in terms of that long view that what we have made here will be judged, and in the shaping of a collective consciousness, mixed but truly native, Bennelong's inclusive view, his imaginative leap, may turn out to have been the most important element in that first and fateful meeting of two worlds.

"mixed but truly native" - seems like a great definition of a Tasmanian pinot.
(And a sound approach towards constructing a special kayak)

Episode 36 - Sanding

2011-01-25T18:22:00.003+11:00

The inside surface of the hull has to be sanded to a smooth finish to accept the fibreglass that will soon be applied to it. So Bill and I worked our way through the hull with electric sanders. The children on their school holidays hid from the relentless noise elsewhere in the house.

And a few final dabs of wood filler were applied to tiny gaps in the wood grain along the surface of the deck.

Episode 35 - The end of stripping.

2011-01-23T20:21:00.001+11:00

Into the final straight with the finger-staining epoxy ...

Strip by strip, the bevilled wood strips are epoxied into place along the deck.

Bill having a morning cuppa.

The hull and its partially stripped deck.

Tony lending a hand with the refining of the storm paddle.

(Lucian providing his opinion of the noise.)

Sanding the whale bone plugs flush with the paddle blade.

At long last the deck is all stripped, epoxied and coarse-sanded. Yee-haa!

Time to fill about 300 nail holes.

Looking a little like a body painted up for a cooroboree.

The next step is to finely sand the deck's surface and then lay it up with fibreglass and resin.

Episode 34 - Removing the deck

2011-01-11T18:27:00.002+11:00

Having carefully fitted all of the deck strips it is now necessary to remove them from the formwork so that the strips may be buttered up with epoxy. But before gluing them back it is time to remove the hull from the formwork too ...

I was expecting this to be difficult however, with a little tapping, the hull separated from the formwork easily. Phew!

Bill cleaning up the inside of the hull.

A joyous moment ... lifting up the hull to find that it is light weight. Back-of-the-envelope calculations of timber volume and density indicate a total kayak weight of 22kgs.

Episode 33 - Forming the bow and stern details

2011-01-09T15:21:00.002+11:00

The bow ...

The stern, with its revised dove-tail detail ...

Episode 32 - Completing the (temporary) fitting of the deck

2011-01-08T19:49:00.001+11:00

The deck nearly complete.

The stripping process is finally finished.

Cato, Lucian, Helena (neighbour) and Felix try out the kayak.

The kayak put aside (hull-side upwards) while ...

... a bbq is fired up using the offcuts of cedar.

Episode 31 - Fitting the deck

2011-01-06T23:40:00.001+11:00

Back in Sydney now, I've taken the kayak home to advance the construction of the deck.

Using a drill to temporarily fit the strips that are under torsional pressure where the deck swoops downwards at the cockpit.

Using the Japanese saw to shape the tapered ends of strips.

Working by candlelight.

Episode 30 - Fire

2011-01-01T07:30:00.003+11:00

With a la Nina event in operation, the east coast of Australia has received a deluge of rain this summer. The coastal woodlands are saturated and lush with new growth. However, as the charred trunks above describe, dry conditions will inevitably return - pursued by fire.

The burning of the landscape is so vital to the process of regeneration here and it contributes to our landscape's distinctive appearance.

I've experimented a little with scorching the storm paddle:

Episode 29 ~ Shaping the storm paddle

2010-12-31T11:50:00.001+11:00

The tribe exploring a sea-cave at Valla Beach, 500kms north of Sydney.

While up here I've completed the shaping of the storm paddle - but, unlike the main paddle (also pictured above), I'm yet to insert the cores of whale bone into its blades.

It was on this beach 8 months ago that I found the whale bone vertebrae that I'm incorporating in these paddles.

Both paddles have been given a lick of tung oil to preserve their exterior. It brings out the golden red colour of the Australian red cedar beautifully.

This cicada dropped in for a visit.

The exceptional structure of its wings might find an expression in the eventual design of the sail for this kayak.

Episode 28 - Shaping the stern

2010-12-22T06:09:00.007+11:00

The smaller section of whale bone has been fitted and shaped at the stern.

I used an electric sander to fair the bone into an ivory-like finish.

Along with the spotted gum outer stem (that's STEM not STERN), the whale bone provides some protection to the strip of Australian red cedar that runs through to the end of the stern. I think that I can improve upon this construction detail so in coming days I may cut it out and rebuild it.

Apparently there was a lunar eclipse this evening but with my head buried in the boatshed I missed it.

This photo was taken about an hour after the eclipse ...

"I looked out my window in the dark

At waves with diamond quills and combs of light

That arched their mackerel-backs and smacked the sand

In the moon's drench, that straight enormous glaze ..."

( Excerpt from Five Bells. Kenneth Slessor. First published 1939 )

Episode 27 - Shaping the bow and stern

2010-12-12T11:24:00.004+11:00

Bevelling the edge of a strip to fit it snugly into the deck.

The bow tapers to a knife-like blade that will surely snap off unless made more robust.

So the plan is to replace this vulnerable section of the kayak with a piece of whale bone which will offer much greater impact resistance.

The same principle applies here at the stern which I'm tackling first ...

The stern detail fixed into place.

Once the epoxy has cured the whale bone will be sanded into a refined shape that follows the original taper of the kayak.

The sharp focus of the bow.

This will receive its whale bone detail in coming days.

Meanwhile, outside the boatshed, the tribe plays at the harbour's edge.

Episode 26 - Bonding the deck chines with epoxy

2010-12-08T17:09:00.008+11:00

All of the thin deck strips that were shaped and temporarily nailed into place (in the previous episode) have today been removed from their unique positions, buttered up with epoxy and then fixed back into their individual places, forever.

This process of building by the wood strip method is characterised by the cliche of taking two steps forward, taking a step back, before taking two steps forward again ....

Bill carefully spreading the ochre-coloured epoxy on to the bevelled faces of the thin wood strips.

You can see above just how thin these three deck chine strips are. At 6100mm in length, 8mm in width and only 6mm in depth, they behave more like pieces of string than wood.

Standing back for a moment to see how the kayak is coming together.

For the curious who have been wondering how the internal formwork will ever be removed:

the hull and deck are not yet joined together. At some stage soon it will be possible to remove the hull from the formwork as there will be a sufficient number of strips laid on the deck to prevent the internal formwork from undergoing any deformation / twisting. When the deck is completely laid it too will be removed from the formwork and then fixed back to its hull.

Placing the partially complete kayak on the flat surface of the tables it was apparent that this kayak will have a nice amount of rocker.

Episode 25 - Port deck chine

2010-11-20T18:31:00.007+11:00

The eight thin strips of the port deck chine are temporarily tacked into place.

And the central deck strip is now fitted too.

It sets out the subsequent parallel sequence of strips to the deck.

As the high foredeck becomes a low aft deck there is a sudden change of elevation along the cockpit. It's not apparent in the image above however this central strip is a continuous piece of wood.

The bow has the potential to be planed into a beautiful and finely tapered point.

However it would either break off or skewer someone before too long.

So this is where the whale bone may be incorporated to form a more sensible and robust leading focus to the kayak ...

The first step is to saw the bone lengthwise to its approximate mid-point.

Then cross- section the bone to form a step.

This bone is extremely solid and slow to saw through.

By way of comparison, it is much denser than the spotted gum used in the outer stems.

It should have excellent properties for impact resistance.

Approximating the location for the whale bone at the fore deck.

It will be slotted and housed within the red cedar strips and then planed into a fine, but rounded, end detail.

The vertical cut face of the bone will abut the end of the spotted gum outer stem.

I hope that this detail will form a nice resolution to this part of the kayak.

A sketch of the detail ...

Similarly, I think that the off-cut piece of bone will be housed and shaped into the end of the aft deck.

Meanwhile the Burrawang cycads of Australia's east coast are fruiting.

This one is at Circular Quay.

The burrawang has the most extensive distribution of any cycad in New South Wales and is found along the coast from the district around Armidale, New South Wales to Bega 700 km south and on the coastal slopes of the Great Dividing Range with some instances on the inland slopes of the range; as far west as the Mudgee district. It is most abundant on the south coast of the state.

The large female seeds are ripe when red or yellow.

The seeds of the burrawang are a good source of starch but are poisonous to eat unless treated. The Cadigal people pounded and soaked the seeds in water for a week, changing the water daily. The pulp was then made into cakes and roasted over hot embers.

Botanical information - Botanic Gardens Trust - Sydney, Australia. Department of Environment and Conservation (NSW).

Episode 24 - Thoughts of an elegant and efficient way to store the kayak...

2010-11-18T13:40:00.007+11:00

End elevation.

A place for a wet spray skirt, life vest, and a pair of paddles.

Side elevation.

This sketch describes the stand from side-on, with the kayak (as a cut-away diagram) supported by pairs of arms.

The cross-bracing stabilises the frame and supports the paddles.

Initial thoughts on the connection details of the timber frame.

Materials to be Aust red cedar, Huon Pine and Spotted Gum.

Prototype model (1:5) of the kayak and paddle rack.

Episode 23 - Starboard deck chine (continued)

2010-11-13T12:47:00.004+11:00

Planing the fine strips for the deck chines.

Temporary tack nailing.

Bow

Stern

Episode 22 - Starboard deck chine

2010-11-02T23:46:00.007+11:00

A most peaceful evening was enjoyed in the boatshed while fitting a couple more deck strips at the careful pace of 6.1 lineal metres / hour.
.

The lines look a little wonky in the image above. This will be adjusted with some delicate tapping prior to setting with epoxy.

These 4 strips of cedar have been heavily planed along their hidden edges to accommodate the radius of the deck "chine" and are now temporarily held in place by tack nails.

The next steps will be to label the planed strips with numbers, remove them, butter them up with epoxy and then permanently fix them back into place. The shear line of this kayak is the lighter-coloured strip of huon pine, beneath my thumb.

The boatshed is a beautifully atmospheric place to work within.

Chiaroscuro lighting and the pleasant sound of small waves lapping onto the shore outside.

Episode 21 - Commencement of deck strips

2010-10-31T14:03:00.006+11:00

The fitting of strips to the deck is, at last, proceeding.

In the typical process of building a strip wood kayak the completed hull would be removed from its formwork and put to one side while work on the deck progressed. I've decided to leave the hull on the formwork to be certain that the formwork does not undergo any twisting while having the deck fitted. Of course it will be necessary to ensure that the deck strips are isloated from the hull - so that both can be taken off the formwork.

As this kayak design has a deck with a fairly tight sectional radius immediately above both shear lines I am using very small cross-section strips: just 6mm x 6mm. I forgot to take a photo at the conclusion of this morning's work but suffice to say that two of these 6.1m length strips were fitted before breakfast.

(It's great to be inhaling the delicious aroma of red cedar again.)

In forming the deck of the kayak it's apparent that the narrow tapering ends of the bow and stern will be exposed to damage and would therefore benefit from having a robust end detail - just as the hull uses Spotted Gum to protect the hull's ridgeline. My current thinking is that a shaped section of whale bone would be a nice way to conclude these tapering fore and aft extents of the deck. I have a section of whale bone collected when on a kayak trip down the east coast of Maria Island, Tasmania, that may just do the trick. I've used whale bone in the construction of the paddles (see further below) so it would be consistent to incorporate whale bone detailing in the body of the kayak too.

Whale frollicking off Sydney last week.

(SMH photo)

Episode 20 - Prototype of deck line spacer

2010-10-11T22:23:00.004+11:00

Over quite a few years I've collected a hundred or so Cowry shells along the east coast of Australia - from the mid-north coast of NSW down to the east coast of Tasmania.

I think that they will make rather good spacers on the deck lines to enable the paddles to be slipped in and held firmly under the tensioned deck lines. This approach is an adaptation of the Inuit's use of whale and seal bones on their traditional qajaqs.

To make the shells robust enough I have simply filled them with epoxy resin, allowed the resin to cure overnight and then drilled through the solid shell lengthwise.

And there it is.

This particular Cowrey shell is from the species Cypraea vitellus.

Deriving components for the kayak from the landscape / seascape that it will be travelling through is an important aspect of this place-specific approach to design and construction. The broader aim of which is to create meaningful things (landscapes, buildings, and artefacts / objects) that engage harmoniously, and at deeper levels, with the unique natural contexts into which they are consciously inserted.

The ultimate aim of this approach is to attain the illusive and higher state of belonging.

Episode 19 - Refining the main paddle

2010-10-10T21:13:00.009+11:00

Overnight the cores of whale bone were epoxy-glued into the ends of the main paddle.

This morning the whale bone was sanded flush with the paddle's surface.

A power sander and three grades of paper refined the paddle's surface to a smooth finish.

The distinctive side profile of this Greenland-interpreted paddle.

The way that the paddle's sectional form evolves along its length from an oval at its centre to a flat ellipse at its ends is very pleasing to the eye.

2300mm in length.

Constructed of Australian Red Cedar, Huon Pine, Spotted Gum and Humpback Whale.

A lick of tung oil and she'll be ready to slip into the harbour

I'd better get cracking on the kayak again.

Intermission

2010-10-04T11:48:00.010+11:00

Progress on the construction of my kayak and its paddles is in a temporary holding pattern while other distractions (domestic duties and work) take precedence.

"Bennelong Point from Dawes Point", circa 1804, attributed to John Eyre.

Anyway, having recently attended the Mari Nawi exhibition at the State Library of NSW, I've been thinking about the following quote (taken from the exhibition catalogue) which refers to the Cadigal people of Sydney Harbour:

"Theirs was a canoe culture and the waters of Port Jackson were their true highways."

(Keith Vincent Smith, Historian and exhibition curator)

Detail from "Bennelong Point from Dawes Point".

The above quote (along with supporting evidence from early observers such as Watkin Tench and John Hunter) makes a lot of sense to anyone familiar with Sydney Harbour's branching waterways. Canoes would have been an excellent form of transport and an effective means for the gathering and hunting of food.

So, if we accept that canoes were indeed central to the Cadigal people, then one would also expect that there would have been some depth of complexity and variety to their canoe designs.

As with the qajaqs and umiaqs developed over many centuries by the Inuit people of the Arctic regions, one might also expect that the Cadigal would have developed specific canoes for specific purposes - such as hunting canoes for the men (fast through the water, designed for launching spears at fish beneath the water's surface) and gathering canoes for the women and their children (stable platforms for fishing from, with small fires on board) - as depicted above.

I understand that, in tradtional practice, some Cadigal men were buried within their prized canoes amongst the sand dunes of Rose Bay along with their most valued possessions - spears and other hunting implements.

Perhaps the formation of a new sand bunker on the Rose Bay golf course or the excavation of a basement to a house in this sandy saddle linking the harbour with Bondi will one day reveal a canoe or two. The detailed study of such canoes may shed some light on the variety of task-specific designs that surely existed amongst the original paddle craft of this harbour.

Zooming out a little, the diagram above (sourced from Austronesian Canoe Origins - Edwin Doran) describes the distribution of indigenous bark and outrigger canoes along the east coast of Australia. (It does not include the reed canoes of Tasmania. And, curiously, it is blank on Western Australia)

The presence of the outrigger canoes in the north indicates the influence of canoe designs from across the Arafura Sea along with the ensuing fact that the people of northern Australia ventured further offshore in their canoes (where additional stability was required) than their single-hulled coast-hugging cousins in the south.

The extensive use of canoes to travel through the Murray-Darling River Basin is also an interesting, and perhaps under-recognised, fact.

It would appear that there is much to be known about paddle craft of the original inhabitants of this large island. Certainly it is clear that there is an extensive precedent for paddlecraft in Australia. And, as with the development of local contemporary architecture, the potential for drawing upon local origins in kayak design is great.

Episode 18 - More shaping to the main paddle

2010-09-16T22:57:00.004+10:00

A roughly planed face of the main paddle.

A roughly planed edge to the main paddle.

A fine edge to the paddles will be achieved with more careful planing and a power sander.

Meanwhile the kayak is in suspension - waiting for its deck to be stripped.

(The neighbouring boat is an open cockpit rowing scull.)

Episode 17 - Refining the main paddle

2010-09-11T10:41:00.002+10:00

Nice morning for a paddle!

Beginning to take on the slender shape of a Greenland paddle.

Episode 16 - Attaching paddle ends, sawing paddles, & core drilling the whale bone

2010-09-08T22:55:00.013+10:00

It is a common detail in traditional Greenland paddles to make the paddle ends out of whale bone. The hardness and durability of whale bone provides the paddle ends with the ability to be thrust into floe ice without splitting the valuable timber.

Now floe ice is not a marine condition that we see much of along the east coast of Australia but there is still a need to have a robust and durable paddle end that can withstand being unintentionally jammed into a rock oyster colony or used as a fender when negotiating tricky rock gardens and sea caves / caverns.

For my paddles I've used exactly the same indigenous timber species used in the kayak's body - that is Aust red cedar, huon pine and spotted gum.

The lightness of the cedar is perfect for the majority of the paddle's body.

The greater stiffness of the huon pine contributes structural integrity along the paddle's axis.

And the density and durability of the spotted gum makes it an ideal material for constructing the paddle's ends.

However, there is something about incorporating whale bone in the Inuit's paddle that goes beyond sound principles of structural engineering and engages with the hunter's respect for the spirit of the animal that he is seeking to capture and ultimately butcher to feed to his family.

Not wishing to lose sight of this reverential aspect and hoping to preserve the memory and spirit of traditional techniques, I've chosen to incorporate core samples of whale bone within the spotted gum paddle ends ...

This is a prototype study of the technique that I've settled upon.

And here is how it's done.

Core-drilling the sawn plate of the whale bone (that I found at Valla Beach earlier this year).

Core drilling the spotted gum paddle ends.

(Incidentally this timber grew on a hillside just up the road from where the whale bone was found)

Routing the paddle blades and paddle ends.

Ian's hand demonstrating how the paddle ends are securely fixed to the paddle blades using a concealed biscuit and epoxy.

In this image the paddles have been roughly cut to shape on the band saw and then epoxied and clamped together with their corresponding paddle end.

And left to cure overnight.

The next step in this process will be to carefully refine the curved surfaces and edges of the paddles with my trusty block plane and spoke shave. Then the cores of whale bone will be epoxied into their holes and sanded to a fair finish with the surface of the paddle ends.

At least in my mind, the spirit of whales migrating up and down Australia's east coast will accompany me wherever I paddle.

Once this pleasurable distraction of making the paddles is out of the way I'll get back onto constructing the kayak.

Episode 15 - Preparing the main paddle

2010-09-05T11:46:00.019+10:00

With the wind on Sydney Harbour gusting out of the WNW at 35 knots the only option this morning was to work inside ...

... with the enthusiastic assistance of a not-quite 4-year-old apprentice carpenter

(who is demonstrating a competent style).

Peeling off long curls of aromatic cedar and huon pine with the block plane is a mesmeric activity.

When the blade is sharp and the block plane is in the groove it's a very enjoyable process.

Standing back for a moment to observe the tapering form of the main paddle from side-on.

On the way back home - an incidental and brilliant display of indigenous flora, glowing in the early Spring sunshine.

Drafting the profiles of the paddle ends onto laminated spotted gum blanks.

A visual test fit of the paddle end piece and the paddle shaft.

The connection between the two pieces will be by way of a concealed mortice.

Rather than replicate the Inuit paddle with its squarish end profile (designed for breaking through floe ice) the design of this paddle's end profile is an interpretation of the small Eora hand paddle ...

Image (by Lesueur ~ 1802) of Cadigal people using a narewang (paddle) in their nawi (canoe) on Sydney Harbour.

Distraction - the paddles

2010-09-02T13:55:00.002+10:00

This lovely photograph of traditional Inuit kayak paddles is an excellent metaphor for the diverse variety of approaches that individuals can generate.

And it also highlights the narrow constraints that standardised mass-production places upon all of us.

To learn a little more about these paddles click here:

Meanwhile, my paddles are steadily being planed into shape when the kayaklings are packed off to bed.

Episode 14 - Preparing the storm paddle

2010-08-29T18:06:00.007+10:00

At 1900mm this storm paddle will have blades the same length as on the main paddle, however its loom is much shorter.

Trimming off the ends of the storm paddle blank with the Japanese saw.

Forming the tapering ends of the paddle with the trusty little block plane.

Meanwhile the apprentice's apprentice takes a cat nap in the boatshed.

The bottom edge of a right angle ruler is used to check that the taper is consistent across the width of the paddle blank. If any daylight was visible under the ruler's bottom edge then that would indicate further local planing is required.

Australian red cedar is often referred to as "red gold".

A tapering end.

The apprentice's apprentice.

Behind the wheel of a block plane at16 months of age.

Episode 13 - Relocation to the harbour. Setting out the paddle dimensions.

2010-08-22T13:22:00.008+10:00

The kayak hull temporarily located within its new home.

A pulley hoist will be rigged up this week to allow the kayak to be quickly raised and lowered for its ongoing construction.

Work bench with a view.

Setting out the critical dimensions on the paddle blanks.

The paddle blade ends will be formed from this section of laminated Spotted Gum - an exceptional hardwood from Australia's east coast. As the paddle will not be needed to break through floe ice an end-profile is being considered which will differentiate this design from its Greenland antecedents.

And this whale bone that I found 4 months ago at Valla will be sawn up to see if the internal bone material is still strong enough to be integrated with the paddle ends.

Day 12 at the workshed - Greenland paddles and farewells.

2010-08-21T21:33:00.008+10:00

Glue-laminated sections of Spotted Gum which will be milled and shaped into the robust paddle blade ends.

A forest of clamps binding the glue-laminated Aust. Red Cedar and Huon Pine sections into the two paddle blanks.

Power sanding of the bonded paddle blanks.

Over the last 3 weeks or so Ian has guided this process of construction with his considerable depth of boat building skills and knowledge.

I'm saddened that the time has now arrived to leave the richness of Ian's workshed in order to relocate the kayak closer to home.

From here on I will be completing the construction of the kayak with many of the techniques and approaches that Ian has generously demonstrated and (hopefully) imparted to me.

Ian Smith owns and operates Woodcraft Boats. http://www.woodcraftboats.com.au/

Day 11 at the workshed - Righting the hull and milling Greenland Paddles

2010-08-19T20:26:00.003+10:00

For the first time in this process the kayak hull is seen the right way up ...

At 6.1m in overall length this kayak spans from one end of the workshop to the other.

I have decided to relocate it this weekend to a harbourside boatshed where I can more readily access it and progress work on it when the kayaklings are tucked up into bed.

But before leaving all of Ian's very useful powertools behind we milled a few sections of Aust Red Cedar and Huon Pine for me to make a pair of Greenland Paddles. Note also the pieces of Spotted Gum (at the far end) which will be shaped into the blade tips. One paddle will be about 2300 mm in length. The other, a storm paddle, about 1900mm in length. Both of these dimensions have been calculated based on my arm / body reach and using the information provided here:

http://www.qajaqusa.org/QK/makegreen2.pdf.

Intermission

2010-08-16T19:49:00.000+10:00

Hands full at the moment.

More kayak building scheduled for the coming weekend ...

Day 10 at the workshed - outer stems, sanding and glassing.

2010-08-07T19:19:00.002+10:00

Overnight three thin strips of Spotted Gum had been glue-laminated onto the leading edges of the bow and stern. This timber is incredibly dense and will provide impact resistance to the softer Australian red cedar and Huon Pine. This Spotted Gum came from the wooded hinterland of Coffs Harbour.

It takes a razor sharp blade to plane the Spotted Gum.

Testing the sharpness of the blade against a thumb nail.

The finely planed Spotted Gum outer stem which travels over the Huon Pine sheer strip and the Aust red cedar hull strips.

An orbital sander provides a fine finish to the timber.

The raw kayak hull.

2010-08-07T19:05:00.002+10:00

Then in the afternoon the kayak was draped in a silky gown of 4oz woven fibreglass.

Preparing the West Systems resin.

Pouring on the honey-like resin.

Slowly wetting the fibre through with resin.

Basting the kayak's hull in resin.

Suddenly it's looking just like a delicious glazed roast duck.

A great day in the workshed.

Thanks to Ian for providing his shipwright's skills and experience.

(Despite visual absence from this documentary the apprentice kayak builder is also doing the odd bit of work)

Day 9 at the workshed - final hull strips.

2010-07-31T14:22:00.001+10:00

A multi-plane was used to roughly trim off the staggered strips of yesterday.

Two rows of strips were then inserted and the precise dimension for the third strip was marked and ...

its path then carefully cut with the multi-plane.

The final strip inserted to form a closed hull.

At this stage the hull is looking raggered - it's covered in epoxy drippings and the timber's surface is rough and unplaned.

The next stage in this process is to laminate fine strips of spotted gum as outer stems to the bow and stern. These stems will provide impact resistance to the less dense cedar.

And then the hull can be planed and finely sanded back to a smooth finish before laying up with 4oz fibreglass cloth and the kevlar ridge strip.

This two-week period of focussed work on the kayak is now over.

From here onwards the kayak building will be advanced whenever time can be found in the margins of life.

Day 8 at the workshed - stripping the bottomside.

2010-07-29T21:05:00.001+10:00

The first activity this morning was the dry-fitting of strips to the hull's bottomside.

These strips are temporarily fixed to the formwork with tack nails to ensure correct fit and the maintenace of form and directionality. Every strip is coded by number. Where the strips are under torsional load (at the bow and stern) they are held in place with washered screws.

The staggered profile of the strip ends will be trimmed tomorrow when additional strips are then laid to close the hull up for good.

The strips being dis-assembled by Bill and Ed prior to being ...

buttered up with epoxy and very carefully laid back in their unique place.

Many thanks to Ian for "sighting" the curves and maintaining the kayak on a straight heading.

Thanks to Bill and Ed for excellent crew work.

The glue-mottled hull is left to cure overnight.

Day 7 at the workshed - flank strips.

2010-07-28T20:45:00.007+10:00

Measuring the tapering gap beneath a chine strip.

Planing a tapered strip to fill the gap.

This is a time-consuming but satisfying procedure of alternately fitting the strip to its gap and planing away the excess "meat", then checking the fit again and planing away a little more until the strip is snuggly housed. The block plane starts to feel comfortable in the hand and the eye is soon distinguishing between fractions of millimetres.

The port & and starboard flanks now closed out.

The stern and bow profiles have been bevelled to accept a series of fine laminated top-strips that will be planed into a razor sharp edge.

Spotted gum may be used here for its increased density and resistance to impact.

Tomorrow's optimistic intention is to lay the cedar strips for the remainder of the hull.

Thanks to Laurie for the advice provided today on laying Kevlar fabric along the hull's ridgeline. It's a really sensible inclusion for kayaks in our part of the world and I'm looking forward to incorporating this innovation with this kayak.

Day 6 at the workshed - a few more strips.

2010-07-26T19:29:00.004+10:00

Another half-day ...

This morning the second and final Huon Pine sheer strip and a few Aust Red Cedar strips were laid along the starboard hull.

Long curls of cedar planed off the tapering wood strips.

The bow with the first few inches of the surface lightly planed to remove the excess glue.

We'll be able to prepare the next Kingfish sashimi with this edge.

(Tomorrow will be spent attending school athletics carnival and chasing up a strip of kevlar for the hull.)

Day 5 at the workshed - a handful of strips.

2010-07-23T20:21:00.002+10:00

A half-day in the workshed begins ...

at the V nice pointy end.

These are the thicker chine strips which have been temporarily screwed in place.

Later in the construction process these strips will be shaped into the hard chines and planed much thinner.

The epoxy that binds the strips together is blended with a small pinch of ochre to ...

... form a colour that will merge into the greater background colour of the cedar strips.

The port-side Huon Pine sheer strip and 3 subsequent cedar strips were then glued and lightly nailed into place along the formwork.

A study in contrasting hull profiles:

the suspended dories floating above the workshed space and the highly directional kayak appearing as though it is about to leap out the door.

The excess ochre-coloured epoxy is forced out of the joints by the pressure of clamping the strips together. This excess material is then roughly scraped away from the hull's surface - leaving the wood looking mottled. This discolouration will be removed when the wood's surface is later sanded back to reveal the brilliant hues of the Aust. red cedar and Huon pine.

Still a long way to go.

But it's tools down as beer o'clock arrives at the workshed.

Day 4 at the workshed - Scarfing and hard chine strips.

2010-07-22T20:25:00.003+10:00

On these crisp Sydney winter mornings the sun is a welcome early visitor to the workshop.

Re-checking the overall alignment and securing the end stations firmly.

The kayak book and scale model are consulted to confirm our approach to laying the hull strips.

By mid-morning the first batch of epoxy-bonded scarf joints were released from their overnight bed press and inspected. Even though it had been a cold night the scarfed joints had all cured well in their tightly clamped jacket.

Each wood strip is coded by row and number in a methodical process of scarf forming, test-fitting, glue application and bonding with its mate.

The remainder of the morning was a focussed meditation of bonding and pressing a second batch of scarf jointed wood strips. Building up a stockpile of these long strips is a necessary process that will make the laying process more efficient.

The larger section wood strips that were completed yesterday are now introduced to their future role as the kayak's hard chines. These strips will be planed back to a thinner sectional depth in the process of shaping the chines.

At both ends of the kayak these deep section strips are severed with the Japanese saw.

Ian adopting a Japanese Zen carpenter's strike position.

We are on the way now.

Day 3 at the workshed - Nose & tail and more scarfing.

2010-07-21T19:45:00.006+10:00

This morning began with tumultuous claps of thunder and lightning.

But the first project of the day was the modest fixing of the smallest station forms - at the bow and stern - to their respective templates. These diminishing station forms will give the kayak its distinctive sharpness of profile.

The fixing of these forms was achieved with a two-part expoxy, bracing blocks and clamps.

Bill test-fitting the stern section.

Ian advised me that it is traditional to arrange the construction of a boat with its bow facing towards the shed's doorway.

The exception to this superstition is if the doorway leads directly to a slipway -in which case it would be stern-first.

We are only 20 meters from the Cooks River however we are without a slipway so we've chosen to follow tradition and aim the bow towards the doorway.

The bow.

In this image a thin strip of huon pine (at my imdex finger) is sandwiched between a "pusher" (in my hand) and the large wedge-shaped "guider". The result of which is a scarf of 1:8 ratio in the huon pine strip.

Bill and I produced 88 of these scarf faces this morning.

Self-portrait with respirator.

It is advisable to use one rather than inhale fine sawdust.

An image of the micro-landscape,

ie, some of the Aust red cedar and huon pine wood shavings scattered around the workshed from yesterday's planing work.

The unheralded aspect of this kind of kayak construction is the amount of preparation that goes into the forming the woodstrips. This contraption is a purpose-built press for simultaneously forming 40 shorter strips of wood into 20 longer strips.

The press with its lid clamped on on to exert vertical as well as horizontal pressure on to the epoxied scarf joints of the wood strips.

With lengthening shadows and a compelling thirst for a beer or three it was decided to call it a day ...

Day 2 in the workshed - Station form assembly and scarfing

2010-07-20T20:32:00.011+10:00

The day commenced early with the "strongback" - a single beam of oregon - waiting in crisp winter sunshine to be transformed into the supporting spine for the formwork that will be assembled along its length.

Temporary positioning of the station forms.

The ends of the strongback have been tapered to accept the fore and aft forms.

Accurately locating the vertical position of each station form with a laser level.

The 1:1 formwork (with its fore and aft forms yet to be assembled).

The handy 1:5 scale formwork model is at left.

This was Ian's clever approach to planing multiple inclined skarf faces at once.

The wood strips in this photo are all of the "specials". That is, the thicker Aust Red Cedar strips (left) which are for the slightly deeper chine sections and the thinner Huon Pine strips (right) which are for the sheer line.

(Why the scarf joints? Because the 5.9m kayak is longer than the 4.5m milled woodstrips.)

A power plane was initially used to form the scarfs.

The horizontal length of the scarf is 8 times the woodstrip's thickness.

A small block plane is used to hand-finish the planing of the scarf.

Bill providing a valuable pair of hands.

Mixing up the West Systems resin for bonding the scarf joints.

Applying the resin evenly to both faces of the scarf.

The scarf joints are clamped and left to cure overnight.

Bill completing the assembly of the strongback's station forms as evening arrives.

With night rain pleasantly falling on the workshed's roof it's satisfying to flick on the laser level and see that all of the station forms are correctly aligned and positioned in three-dimensional space.

Thanks to Ian and Bill for their valuable guidance and assistance today.

Supporting structure

2010-07-18T20:30:00.006+10:00

A big thanks go out to JK. for volunteering to spend a sunny weekend with a bandsaw to cut out the kayak's station forms in 12mm MDF.

This adventure is more than a project to build a kayak.

It is an odyssey with fine friends participating in the voyage.

Experimenting with fire

2010-07-17T20:44:00.008+10:00

One of the specific intentions with the design and construction of this kayak is to imbue it with a direct and harmonious relationship with the east Australian landscapes along (and into) which it will be paddled.

One of the key elements influencing the unique qualities of the Australian natural environment is the impact of fire.

It is a source of destruction and renewal.

Echuca Saplings (Forest Series) 1961. Fred Williams

This defining characteristic of our landscapes has been compellingly interpreted by the insights of others ...

such as Fred Williams.

With this in mind, perhaps there is an opportunity to interpret and represent the influence of fire on Australian landscapes with this kayak.

Time to get out the flame thrower...

... and experiment on one of the woodstrip battens.

Yep. This could be good.

Day 1 in the workshed - Milling the timber

2010-07-10T18:46:00.015+10:00

In Sydney's mid-winter sunshine Ian plots the best way to mill the large sectioned beam (100mm x 250mm) of Australian Red Cedar into the many fine sectioned strips (6mm x 19mm) required to form the deck and hull.

Ian's sketch describing the arcs of the beam's end grain and the way in which the beam will be ripped into sub-sections using a hand-held power saw. The purpose of which is to arrange the long face of the wood strips at an approximate right-angle to the wood's end grain.

The first cut.

On the left is the table saw for the accurate milling of the fine strips.

Achieving a fair face to the ripped beam with the assistance of a power sander ...

and then a razor-sharp block plane.

The cool morning air of the workshed is suddenly infused with the aroma of an east Australian forest.
A beautiful and unforgettable experience.

To this heady atmosphere is released the perfume of an ancient Tasmanian landscape when the Huon Pine is ripped.

Marking up the ripped beam of cedar for the finer milling of the individual wood strips.

Hand planing a ripped section prior to putting it through the table saw to create ...

a kayak's worth of fine Australian Red Cedar and Huon Pine wood strips.

The 1:5 scale study model

2010-07-04T15:54:00.006+10:00

I'm not certain that flush hatches will be thoroughly watertight but the intention is to give them a go as they minimise the number of deck lines.

See here for more info ... http://www.clcboats.com/shoptips/fitting_out/hatches_no_toggles.html

The deck layout.

Sail rig stowed along the port bow.

Retractable dagger board secured on the starboard stern.

One of the intentions with this kayak design is to be responsive to the local physical conditions that this kayak is most likely to contend with.

Sydney beach sand is often like a coarse grade sand paper so the proposal here is to lay a defensive strip of kevlar along the hull ridge.

Thanks to Nadgee kayaks for this idea:

http://nadgeekayaks.com.au/accessories.html

Okay - now it's time to build the 1:1.

2010-06-26T15:43:00.026+10:00

This is the modelled prototype of the sail rig.

It's a V-sail with a high dergree of transparency.
A similar sail can be purchased from Gary at:
http://www.pacificaction.com/

Retractable dagger board and retractable skeg / rudder system deployed.

The majority of the hull and deck will be constructed with Australian Red Cedar,

A thin strip of Huon Pine will be used along the shear line.

Tools

2010-06-26T15:37:00.001+10:00

Some of the tools that will make this kayak.

1:5 model

2010-06-14T17:54:00.001+10:00

With Ian (the boatbuilding mentor) away for a few weeks investigating timber boats in the UK and the US, the commencement of the real kayak is on hold until mid-July.

Meanwhile the 1:5 model is being used to as a prototype to test the positioning of hatches, bulkheads, the retractable dagger board and the retractable skeg / rudder system.

These images show the set up under full sail when the dagger board and the skeg / rudder are deployed. The sail rig is yet to be made for this model.

2010-06-14T17:52:00.005+10:00

Kayak boy #2 enjoying the process of prototyping the kayak with GI Joe demonstrating the traditional Greenland Paddle.

Forest / woodland

2010-05-18T21:24:00.003+10:00

I've been thinking that there is great potential for the distribution of different wood colours used in the kayak's deck to generate a "dialogue" with the landscapes along which the kayak will be paddled. That idea, afterall, is at the core of this project.

Rather than have two rigidly formal and contrasting fields of colour on the deck (as my sketch a little lower down this blog indicates) it will be more meaningful to use a relaxed arrangement of the cedar and pine strips to generate a visual effect not unlike the beautiful painting below ...

Saplings Forest. Fred Williams (1962)

The closest precedent that I have found to demonstrate this visual effect in a kayak is captured in the images below of a Guillemot Expedition Single.

It's a very nice approach and, it would seem, clearly inspired by the repititious verticality of the forests from which the timber has been sourced.

Ongoing design refinement

2010-05-17T13:54:00.005+10:00

While the timber is being milled, and prior to fabricating the formwork, there are ongoing refinements being made to the design.

As the brief for this kayak requires it to sail (with effectiveness) to windward the retractable dagger board will be positioned forward of the cockpit where it provides greater righting moment to the over-turning moment generated by the large sail area. This dagger board will only be used when under sail. Where it becomes necessary to maintain tracking in strong wind or when catching waves / steering under sail the retractable skeg / rudder will be deployed.

Concepts for arranging the combination of Aust red cedar and huon pine strips along the deck are being generated to reinforce the arrow-like directionality of this kayak. It may be possible to also acknowledge the position of other elements along the foredeck - including the compass, dagger sleeve and mast-step.

Workshop.

2010-05-14T20:54:00.006+10:00

A small milestone in the project was reached today with a trip to the boat builder to deliver the timber and discuss the milling process. The boat builder - Ian - will guide and assist me to construct the kayak over coming months.

Australian Red Cedar.

This magnificent beam is 100mm x 250mm x 4500mm.

It will be stripped to form the majority of the deck and hull.

The timber was sourced from Mapleton, Qld.
(Thanks to Dennis W.)

Huon Pine.

20mm x 200mm x 2500mm.

This beautifully aromatic and buttery coloured timber will be stripped for use as a highlight on the foredeck.

It was sourced from a Tasmanian forest.

The two battens (with drill holes) lieing on top of the Huon Pine are Spotted Gum.

They will be formed into the fore and aft hull ridges to give the kayak some robustness when paddled onto rock platforms and into shelly beaches. This Spotted Gum was sourced from a forest behind Coffs Harbour, NSW. The battens are salvaged leftovers from a building project of 4 years ago (thanks to John K.) and they have patiently resided in the garage until this day when their new future begins to unfold.

I'm using a reference book to guide the construction process.

The kayak design is derived from the striking profile of the Tahe Marine Greenland T but adjusted to be 5.9m in overall length and with greater internal volume for extended expeditioning.
The kayak will be fitted with a large sail, a retractable carbon fibre dagger board and a retractable skeg rudder system http://www.seakayakservices.com/Kari-Tek.htm.
(Thanks to Pete for this great suggestion.)

The 1:5 model kayak formwork - looking a little like a beached whale's skeleton.

The 1:5 model kayak.

(The hands belong to Ian - my boat building mentor.)

The next step in the process will be the milling of the strips - possibly next weekend.

Meanwhile refinements to the sectional design will be advanced prior to fabricating the station forms.

Design development sketch

2010-05-14T19:26:00.003+10:00

An early sketch where the centre board was placed behind the cockpit..

Stage 2

2010-04-13T21:26:00.000+10:00

Construction of the 1:5 scale model is underway with the hull now partially stripped along its temporary formwork.

This scale of model is great to work with.
It is assisting to define where the wider strips (19mm x 6mm) and thinner strips (10mm x 6mm strips) of the 1:1 kayak will need to be laid to suit the hull's fairly hard chines and steep elevational curvature. Building the kayak as a model also allows the total quantum of strips that will be required for the milling of the actual kayak to be accurately estimated.

Kayak boy provides some scale for the 1:5 model

2010-04-13T21:25:00.000+10:00

On this second model I've used a different setout arrangement for the hull strips as compared to the first model.
To give lineal emphasis to the hull's ridge line the central strips of Model 2 are arranged parallel to the kayak's long axis - unlike Model 1 where they had been arranged in a pattern of concentric arcs. The lineal arrangement offers a distinct constructional and structural advantage as these continuous ridge strips provide a neat and solid resolution to concluding all of the other strips along the hull's sides.
Additionally, these central strips can be specified as a timber of greater hardness than the Australian red cedar and huon pine used elswhere in the hull and deck. This will provide the hull with additional protection along the ridge line - this is benefitial to a kayak paddled along the abrasive coastlines of eastern Australia .

2010-04-13T21:20:00.000+10:00

Stripping of the hull (left) and deck (right) now completed.

AIM:

2010-01-01T22:01:00.009+11:00

to design and build a sea kayak that forms a harmonious dialogue with its east Australian coastal land & seascape environment.

A sea kayak that is:

- responsive to the specific physical conditions encounted along the east Australian coastline;

- principally constructed of materials that are sourced from the east Australian coastline;

- accommodating of the large storage volume required of multiple-week expeditions; and

- capable of being sailed upwind.

The principal building material for this kayak will be Australian red cedar.

A young Australian red cedar tree growing behind Valla Beach on the NSW mid-north coast.

2010-01-01T21:55:00.005+11:00

Acknowledgement:

The initial design direction for this adventure into kayak design is sourced from the strikingly elegant profile of the mass-produced kayak shown above - the Greenlander (T) from Tahe Marine - which itself is derived from tradtional Inuit kayak designs.

I have adapted this contemporary interpretation further to suit my brief for a kayak that is significantly longer in overall length at 5.95m. This adaptation dispenses with the space-eroding skeg located in the rear compartment in favour of a retractable centreboard located in the cockpit. The deep blade of the centreboard will provide righting moment and tracking for a large sail. The incorporation of a retractable rudder will provide additional directional control when under sail.

An early sketch in plan and elevation.

The initial sketch translated into a CAD set-out of "form stations" and "strongback".

The set-out drawing (above) included the rear skeg of the Greenlander (T)- but this was subsequently dispensed with in favour of the retractable centreboard, as described below.

2010-01-01T21:52:00.002+11:00

The commencement of a 1:10 scale model to study the three dimensional qualities of the design ...

2010-01-01T21:49:00.001+11:00

The timber strip method of construction is used to form the hull and deck.

2010-01-01T21:47:00.000+11:00

2010-01-01T21:44:00.001+11:00

Formation of the coming to the cockpit.

The double curvature of a cuttlefish shell provides the perfect formwork for the shaped seat.

The centreboard housing is located between the thighs. The centreboard is only inserted when under sail.

2010-01-01T21:41:00.001+11:00