Background I’d seen a number of skin on frame kayaks for years and they had always been under the category of “Why?”. Unlike most kayaks you can’t find a local dealer and take it out for a spin. A friend had mentioned Cape Falcon Kayaks but the idea of spending time and money building one and then saying “Nah, don’t like it”, or worse, building one that would only paddle in left hand circles while slowly sinking kept me away. I did finally tried a F1 in heavy water where I’d been struggling with my glass kayak and the difference made me willing to try.
My purpose for this blog is to keep track of what went unexpectedly well or unexpectedly bad. Brian has done an incredible job of saying what things should be so I’m not going to spend a lot of time duplicating what he has already done.
As in all things I do, I anticipate that this project will take a while, just because.
12/15/2020 Prepping the workspace
First things first, I cleaned out the basement, smaller than Brian’s recommendation but I had no plan B, and built a new table. The table had an added benefit of making a good infeed table for ripping. The 2×6 made for a good outfeed table.
12/30/2020 Gathering materials
The majority of the wood came from Compton Lumber. They only had 16 footers, which also turned out to be a stroke of luck. I was able to trim the gunnels to 14 ft. after I screwed them together which meant they were exactly the same length and I had 2 feet left over for morticing trial pieces. It let me dial in adjusting the mortice jigs and make all my mistakes on scraps.
1/28/2021 Making morticing jigs
The morticing jig I made was slightly different than the one Brian uses. The major difference is that his is attached to the router and you slide it along the work piece. For the one I made the jig is clamped to the work piece and the router slides in the jig. Once I made the jig there were fewer ways to screw up, although it is slower to use than Brian’s jig. Once I used the jig for the rib mortices I repurposed it for the deck beam mortices. It also allowed me to keep both hands on the router at all times. I did manage to mess up a little. I found that the rib mortices were getting a little deeper as I went along. It turned out that every time I did a plunge the plunge stop moved just a little. Gentleness and an eye on the depth gage solved the problem.