Composite Surf Kayak Build


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Junior
Junior
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So what construction would you recommend for the type of kayaks I have pictured as a minimum? Not designed to run down rocky rivers, just to surf on waves but be able to take a scrape or two coming into the beach?
Warren (Staff)
Warren (Staff)
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Kite boarding is a completely different situation to kayak construction.  I have heard of similar layups being used for boards but the specifics of the board and its likely use would need to be known to make a good judgement call.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant
Junior
Junior
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Can any of the EasyComposite staff lend some advice?

I've read some threads from other forums about Kiteboarders using 2x 200g CF either side of a foam core.
Junior
Junior
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So thicker layers would be stronger than multiple layers of a similar weight?

By my calculations, if I were to use a total of 5 layers of 650g (2 on top and 3 on the bottom) it would weigh around 8.3kg.
Edited 8 Years Ago by Junior
FLD
FLD
FLD
posted 8 Years Ago HOT
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For something with a vague resistance to knocks against the bank or rocks I'd be looking at 2 layers of 660g outer-foam-1 layer of 660g.  I'd also recommend sticking an extra layer on the inner and outer at the ends for around 6-8 in.  For the deck you could use 1 layer of 660-foam-1 layer of 660.  You should be using epoxy resin for this.  For the short, bouncy, boats aimed at air loops etc this should give a nice rigid boat that isn't too heavy.  It will resist knocks to some extent but it'll be no placcy boat.  For the seams I'd say 4 layers on the inside and 6 on the outside.  Again for the short boats you'll be fine to get right round without need for an end pour.  For anything 'slicey' you'll need to do an end pour of resin with chopped ends.

You could lessen the thickness if you need to go lighter but it's something to paddle where there's no rocks.
Junior
Junior
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So how many layers would you recommend with something like Carbon/Kevlar?
FLD
FLD
FLD
posted 8 Years Ago HOT
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Nice toys there!  I keep thinking about building one but with dodgy shoulders there doesn't seem much point.  Looking at your layups they are on the fragile side.  I used to paddle a bit of slalom and my K1 was a hull of 660g-foam-2x200g.  It was fairly robust but I wouldn't want to have been scraping any rocks with it through fear of 'zippers'.  I had a squirt that was a 200g followed by 6 (yes count them, a whopping 6) layers of 450gsm CSM.  Whilst CSM is the probably the weakest fibre choice it's also cheap.  If I were to do a kayak I'd do one in CSM first to give it a try.

WRT foaming up to the edges of the moulding my previous boats were done like this.  The seam tape seals the edges so there shouldn't be a problem.  6 layers on the outer seams and 4 on the inner.  I use 1" tape to start then go to two.

Have a look for some alufibre I think a boat looks nice in this.
RedLegsGear
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Yes the carbon will damage more easily. But also easier to repair. 
 I've not decided completely yet but am thinking something along the lines of
 2x2 twill, Kevlar, Kevlar, biaxle, UD, biaxle
Junior
Junior
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A few more questions in addition to my first ones!

1. When using a foam core (e.g. in a kayak hull), should the foam run right to the edge of the laminate? And if it should, how do you seal the ends?

2. Thinking about the design, I would like to have either an orange or white gelcoat for the top half, but have transparent decals (such as writing) so it shows
the Carbon underneath. How would I go about achieving this?

3. After watching this video... https://www.youtube.com/watch?v=0N-LiWRA7RQ
I have also been intrigued by Innegra and wonder whether this could be used within the layup to achieve a better result? Could someone explain what effect it
would have pairing it with Carbon, Carbon/Kevlar, S-Glass & Diolen in terms of kayak strength and durability? Would it work either side of foam core with one of the other
composites on the outside?
Junior
Junior
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What lay-up are you going for?

Won't carbon on the outside damage easier?
GO

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