Returning to the computer in the fall of 1996, I spent 2 weeks redesigning the kayak and engineering a more efficient layup. The next logical step in our construction methods was to vacuum bag the assemblies, and this we determined to do.
For this next mold we again used particleboard and stringers. The photo shows the mold partially covered in foam. We used the foam only on the mold - it did not become core for the boat.
Spray painting the finished mold.
After laminating the mold, we vacuum bag it.
The epoxy has cured and we have removed the vacuum bag and are peeling back the breather/bleeder ply and the release film - exposing the new hull.
We unfasten the mold from the strongback, roll it over and place the assembly in its cradles. We then trim the excess lamina beyond the sheer.
Lath resting on the new hull, indicating the position of the bulkheads.
For hull stiffeners we used strips of 1/2" small-cell styrofoam.
After covering some of the strips with carbon and some with s-glass, we vacuum bag them to the hull.
Bulkheads standing in position.
Bulkhead kevlar-tape being vacuumed into place.
We have returned the mold to the cradles atop the strongback, and covered the open deck with foam. Here we are fairing and longboarding the deck mold with polyester putty.
After vacuum bagging the deck, we remove the assembly from the strongback and make a set of deck cradles. Then we place the new deck in its cradles, and envelope-bag various under-deck stiffeners to it.
The underside of the deck, showing the stiffeners. The cockpit openings are intentionally undersized for extra strength prior to assembly.
The hull and deck prior to assembly.
The hull and deck have been seam-taped together, internally.
Post curing the kayak in an autoclave made of expanded polystyrene.
Envelope bagging a hatch cover.
The completed kayak, Nunaluk ready for its summer of Arctic adventure.
Please note: These photos and descriptions are for general interest only. With apologies I do not have time to answer questions about them.
