Attach Deck to Hull

The general process is to lay the deck on the hull with support sticks, insert copper wire for stitching, but do not tighten. Next mix up some thickened epoxy and apply to the top of the hull sides here the deck will rest. Then remove the support sticks and tighten up the stitches. Then tack weld the deck to finish the first part.

Once the tack welds have cured and the kayak can be placed on it’s side without fear of the deck shifting. In the next step 3″ fiberglass tape is applied to the inside deck to hull seams. This was one of my least favorite parts of the build. The approach here is to cut the strips of fiberglass tape to length to fit in each of the three sections of the boat, fore, cockpit and aft. The tape is pre saturated in epoxy, and using a chip brush head on the end of a hockey stick reached into each area and did my best to reach and smooth the tape.

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