2 new build’s in Sweden !!

May 2018, an Idea is born…

Last time long-paddling in a kayak was 1987 ! It was a 2 weeks tour to the Norwegian Fjords. Me and my wife had 2 greenland inspired kayaks that we imported from UK 1982. They where 5m long and 58cm wide and had very tight and small cockpits. Very nice Baidarka models.

Now, 30 years later… Some weeks ago my olde’s daughter did a evening trial paddling. I started to goggle and found Cape Falcon Kayak web site. It took a week and three… four mails to Brian and another builder in north Sweden and I had bought the fundamentals for build of one F1 for my daughter and a LPB for me. Despite Brians video recommendations … I thought I need a bigger kayak than the F1 to distribute my additional new kilos since 1987. And I want to re-live my old kayak that I sold 1992. The build plan has been made and looks like the following:

  1. July. I hope Brians deliver as promise everything we need (coaming kit and accessories and ribs) – DONE
  2. August. Prefabricate all parts and build of deck – DONE
  3. September. The ribbs and keel to be build. A bit scary, when I see all blogs, but I look forward to it – DONE
  4. October. Skin mounting
  5. November. Painting. What color to take?!
  6. December. Too cold water to test new kayak. Only look and dream
  7. January. Ice in baltic sea, so impossible to kayak
  8. Febuary. More ice on baltic sea
  9. March. Water cold as a drink full of ice-cube’s
  10. April. FIRST TRIAL PADDELING
  11. New life, restart an old dream

Please follow us to see the progress on our build’s and help me improve the result by giving me hints, tricks and please share your learnings !!

On the blog I miss pictures and videos on the cape falcon kayaks in the water. Please page more usage pictures and videos from expeditions or short tours!!


June 2018, Starting the build . . .

So finally we started our build of the F1 and LPB kayak’s. The day started with understanding the US way of using inch dimensions. In Europe we cut everything by using meter and millimeter. First we downloaded an app to our cellphone’s but is was both boring and time consuming. So we thought we need to build and think in inch from start. I found an old “tumstock” (folding role) with both scales :)) Perfect. Now let’s start !!

The forms and jigs, the steambox and the deck bending jig was build. We also arranged a 16′ long working bench. Without the saw bench this would have been a hard task, now it was done within half a day.

Next will be to find and buy the right materials.

8 Forms ,

One steam box, painted on the inside, using a wall paper remover as steamer (4 liter)

A jig for the deck beam’s. We will only glue one at the time

Portable workbench 96” x 24” . . . . besides the one I already have. The open ends on the bench are needed for the long parts

. . . and a 16′ long for the build of keel and ganwales. I just place it on the newly build bench


July 2018, Pre-fabrication . . .

This weekend we transported the ceder wood we ordered last week, 2 pieces of 16 feet blanks for the long stringers, keel and gunwales and 4 blanks for the 4 paddels (all with 6×2 in section). It took us 3 hours to cut out everything from the blanks. Everything is now ready, nice and straight, only fine tuning left. Deck beam material is also cut and first two in production.

Two Kayaks on the car roof ;)). Next time I hope with skin and ready painted for the first trail test…

2 blanks 16 feet long Canada red ceder

And now cut into 4 gunwales, 2 keels, 10 different stringers and 4 paddel blanks. Strange I think is that the foredeck stringer has same dimension/lenth on LPB and F1 kajak in the drawing, I hope it is no typing issue by Brian :))

Nice looking deck beams 30 pieces, good for 6 beams

First 2 ready, wow, how stable it gets when its glued !!

Everything is now glued and ready finished. 8 pieces should be enough to fail in the cutting process later on. The 4 gunwales are also ready into length/ hight and all cuts.

We did 108 cuts, most of them look good, some a bit shaky and not full straight but it will work just fine I hope.

To do the straight beams cuts in the gunwales with 25 degree angle we used a drill. That was more complicated than we expected. We used a jigg however the gunwale’s are slightly thicker than drawing so the jigg did not fully match and the cuts where very close to the corners of the gunwales on the outside, still half inch down on inside and 25 degree angle – the cut came out close to or on the edge on the outside of the gunwale. I hope the strength will be there anyhow.


August 2018, Deck assembly

First deck in jig. Dimensions looks to match, we feel proved managed so far. Now we need to start assembling process of the F1 deck.

and now we assemble everything together, to the book of Brian ;))

Assembly and pegging of curved deck beams was fairly easy,

Here also som not very perfect results. when mortise the straight beams the jig gave us some issues. I think however this will work anyhow. We will fill the gap with epoxy so it does not damage the skin later on.

Nice curve when ready. I assume the curve come from the geometrical fact that we bend the gunwales with a 25 degree angle. The shape looks very consistent. Same on both sides

Now we plan for the steaming and bending the ribs.


August/september 2018; Ribbes, keel and stringers

Full speed in the build. Yesterday we prepared all ribbs and the steam-box and today was the D day. The day where we when from the category “none ribb-bending people” to “ribb benders”. The material, oak, was bought from Brian. So we hoped to get the best of quality. And gess what. It was perfect. No cracks, Every ribb we bended worked fine, frim first trial rund to the last. We steamed 7 in the box with 1,5 min interval so in total 9 min per ribb. Just perfect. Smooth rythm, relaxed and very hot in the garage. Weight incl coaming the kajak has now a weight of 9,8kg.

Our steam box. Worked 100%. 4 liter water was enough for the complete boat. No refilling was needed. 

All ribbs cut and adjusted to fit in the gunwales. We got 2 small cracks in the gunwales during ribb assembly but these we will glue later-on

Very nice an smooth lines. If it looks good it normally works good. 

Now only skin and paint left ;))

I was supprized about the stringers and the forces they needed to take during assembly. Before I though the keel would be critical but this was much easier to assemble. When everything was tied up the frame got very robust and stiff. Good. 

Im still wondering how my weight will be distributed into the frame w/o damaging anything. 

Nice view.  Next step: The coming 2 weeks I will do the LPB build to the same stage as the F1. I can imagine it will go faster now when I know what to do.

This week I have been building the LPB, same process as the F1. Everything went as perfect as it can when you know what to do. One evening assembling deck, one evening preparing keel, stringers and stern(bow, one evening preparing the ribs and then saturday to steam ribs and assembling everything.

Now 2 nice boats. In September we start skinning them

I build a frame to store them as well. I believe they design of the kajak’s makes it best to have them upside down and 1/3 in for the stand.

Below a movie that shows the frame ready and coated. Next step is the skinn! We are very happy reaching this level.

Next blog update will be end September when we start skinning the boats. Now its other topics on the agenda.

– – –

Andre

View posts by Andre
Born 1965. 1985-1992 kayaking around in Norway and Sweden. Now I intend to restart this!! I love water, sailing, camping and scuba diving.

5 Comments

  1. Paul Hitchman
    July 25, 2018

    Hi Andre, I jumped to this blog as we are both in Scandinavia. I’m in Finland but originally from the UK. I’ve been here for 30 years and all that time I’ve been sitting behind a computer making corporate magazines and digital marketing for forest industries. However I just completed a 17 months course in boat building and I’m building a 21ft John G.Alden Indian Class day sailing boat. My interesting in boat building came from an interest in kayaks. So I was looking for something to do while I’m stuck at home recovering from a double hips replacement. Now 5 weeks after I’m in a position to start my building the forms etc.

    Reply
  2. Andre
    Andre
    July 25, 2018

    Thx for reading. Im just a humble dreamer. Let’s see if it will foat when ready. The drawings and video tips done by capefalcon are super and we learn a lot.

    Reply
    1. Paul
      July 26, 2018

      Same here, ex graphic designer an web artist struggling to find a craft and build something to touch and feel and leave my kids. Life would be miserable if all they got to show would be a USB memory stick with some .fbx files on it 🙂

      Reply
  3. Ola Friström
    July 30, 2018

    Looks nice Andre, I am glad that you decided to build the Cape Falcon kayaks. Soon we can start a Scandinavian CapeFalconKayaks community 😉 It will be interesting to follow the progress of your building. I hope that I will get the chance to see your kayaks IRL at some point and compare with my F1 and see what it looks like when you have had access to Brians instructions.

    Reply
    1. Andre
      Andre
      August 01, 2018

      Thx :))

      Reply

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