Building the Sea Kayak

Hull with cable-tie stitches sanded off and fiberglass tape on seams.

Since I had a world of boatbuilding experience under my belt (see Foamee), I decided I could play fast and loose with the plans. Specifically, I realized that there was no way I was going to be able to run fiberglass tape all the way down the inside seam of deck-to-hull. So I bought a few 1/4-inch quarter-rounds from the hardware store, sort of like a dowel sliced lengthwise into 4 parts. I think they're meant for window trim. I glued them to the hull 4mm below the sheer and held them in place with clothespins while the glue cured. I used 1/2-inch cove trim on either side of the top of the bulkhead. Then I sanded the edges of the decks to fit and just glued them to the bulkheads, breasthooks, and each other. I held the decks in place with blocks of wood along the sheer and cargo tie-down straps, instead of stitches. Next time I'll place the quarter-rounds at sheer height and glue the decks on top, which will reduce the amount of cutting and fitting and result in a better fit on the decks.

Bulkheads and deck support strips in place.

Next time I will also cut the edges of the bulkheads slightly undersize and bed them epoxy putty instead of bending the hull around them. There is a slight bulge at each bulkhead that should be a more natural curve in the hull.

Attaching the deck by any means necessary.