Synopsis: Chris Kulczycki explains a technique that will help you build a sleek, handsome kayak for less than a few hundred dollars in less than two weeks and with little more than a jigsaw, block plane, hand drill, and a pair of pliers. It’s made using compounded-plywood construction to form the hull halves. Wood screws, staples, and copper wire ties are all used to hold pieces in place while epoxied joints cure. He covers the materials needed, how to make the hull panels, how to join the hull, and fit the deck. He talks about the coaming, seat, and trim, and how he finishes his kayaks. A detailed project plan and a glossary complete the article.

Building a boat is something many woodworkers have thought about but often dismiss. It takes too much time, money and specialized skills to build a boat, right? Not necessarily. With the technique I describe, you’ll be able to build the sleek, handsome kayak shown above for less than $200, in less than two weeks and with little more than a jigsaw, block plane, hand drill and a pair of pliers.

In the early 1960s, a technique known variously as compounded plywood, stressed plywood, developed plywood, and, most descriptively, tortured plywood was developed for building multi-hull sailboats. Soon thereafter, an Englishman named Dennis Davis developed several kayaks using this method; all of today’s compounded-plywood kayak designs are based on Davis’ early work.

From Fine Woodworking #95

For the full article, download the PDF below:

Fine Woodworking Recommended Products

DeWalt 735X Planer

At high speed, the planer works fast and leaves a smooth surface. But the slower, finish speed produces an almost glass-smooth surface. Knife changes are easy.

Buy at Amazon

Bessey EKH Trigger Clamps

Bessey EKH series quick-release trigger-style clamps are simple to use and maintain consistent pressure. Trigger clamps that perform the way you've always wished they would!

Buy at Amazon

View PDF