The modern skin-on-frame kayak is a traditional ultralight craft. Half the weight but stronger than a fiberglass sea kayak. Modern hulls meet traditional build.
Wood Selection and Cutting
Starting from either logs or lumber, the red cedar is hand-picked (1 board per 10 chosen). Then it’s milled to tiny dimensions.
Marking and cutting tenons
Marking and cutting the tenons of the deck beams is very precise and is a complex boat-building specific process. We use japanese saws and other ultrafine hand tools.
Creating the mortices
The deck beams must fit perfectly into the mortices of the boat’s gunwales. This is done carefully by hand, and then the deck beams are pegged into place.
Steaming and bending ribs
Steaming and bending the bamboo ribs is definitely an art. Each rib must be bent to a distinctive shape, and within 10 seconds of exiting the steamer.
Lashing the stringers and ribs
All the kayak’s parts are lashed together rather than being secured by metal fasteners, making the boat far stronger and more flexible.
Bending the kayak coaming
Steam-bending of the coaming is fast and furious– with three separate layers, it is laid onto a form and then clamped until set.
Sewing the bow and stern skin
As we begin to sew the skin on the boat, the bow and stern are very fine and are fitted carefully to create a seam that will become waterproof.
Sewing the skin
There are two completely separate stitches used to sew the skins on, one to tighten and tension the fabric, the other used to create the final seam.
Sewing the cockpit coaming
One of the most difficult parts of the process is sewing on the kayak’s cockpit coaming, which is must be done in a single stitch while maintaining tension.
Coating the skin
The completed skins are coated with a skinboat-specific polyurethane, which is colored by earthen pigments. This process is finicky but results in beautiful skins reminiscent of sealskin and driftwood.
No kayak is complete without its complement of deck lines, seat and back brace. Lines are sewn through the kayak’s gunwales making for towable seaworthy straps and a traditional deck layout.