Add a Woodstrip Deck to a Kayak

Today someone asked me how I added a custom woodstrip deck made out of Western Red Cedar, to my Mill Creek 13 kayak. What follows is the process I used.

The process involves making some forms to support the deck, give it some shape and allows for a place to staple the deck in place while the wood glue dries. Once the deck is finished being built and sanded,  I remove the deck, and thus removing all of the staples, flip it over and sealed the underside with epoxy and glass. Once it’s cured I use fiberglass cloth and epoxy to glue it onto the shell.

First, create the forms. I used MDF I had around the garage left over from some cabinets I made. The forms are only temporary so use what ever you have available. I used the original templates used to shape the shearclamps to transfer the arc onto the forms, and then cut them to shape with my bandsaw (if you have a jig saw that works too. I used hot-melt glue to hold them in place in the boat shell.

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A close-up of the forms during a test-fit

I spaced the forms about 12″ apart   Continue reading