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Applying a Fill Coat

A "Fill-Coat" is what I call the coat of epoxy applied after fiberglassing which is intended to fill in the weave texture of the fiberglass so that it can be sanded smooth.

Installing a Solid Outer Stem

There are a couple ways to add an external stem to a kayak. While I typically use thin laminations stacked and bent and glued in place, on these boats I want a solid piece of curly maple.

Joining the Deck and Hull and Taping the Inside Seam

Joining the Deck and Hull

One of the more frequent questions I get is; "How do you put the deck back on the hull?

Smoothing the Hull Interior

The concave shape of the interior is more difficult to smooth than the exterior. The easiest tool to use is a scraper. These scrapers are not card scrapers but more like paint scrapers.

Glassing the Interior of the Coaming

To this point I have only glassed the outside of the coaming. Now that I have applied carbon fiber to the interior of the hul I can proceed to glassing the other side of the coaming.

Laying Carbon Fiber Cloth on the Deck Interior

Laying carbon fiber is not that different from fiberglass accept that it is black, and stays black. Where fiberglass starts white and becomes transparent when saturated with epoxy, carbon fiber stays opaque, so it can be tricky to tell if it is fully saturated.

Smoothing the Deck Interior

Unlike the outside where sanding is easy, the inside can be harder to to smooth. I find scrapers are the easiest way to deal with the concave surfaces.

Fiberglassing the exterior of the Coaming

After installing the riser, I glassed the outside, reinforcing the coaming and securely attaching it to the deck. The riser was initially installed using hot-melt glue which is not particularly strong.

Installing the Coaming Riser

The coaming "riser" is what I call the vertical part of the combing around the cockpit. This is made of the same wood I made the rest of the boat from. For efficiency reason I want to use the 2" wide strips I have, but these don't conform to the sharp curves at the front and back of the coaming.

Fixing a Broken Seam

While rolling out the fiberglass before glassing the deck, I ended up cracking a section on the back. The break was along a glue line.

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