Bobby’s F1 build, Seneca, SC

I’ve been kayaking for 5 years and recently had upgraded to a P&H Cetus HV sea kayak. I really love the kayak but wish it was a few pounds lighter. I joined the “Greenland Inspired Kayaking” FB group and started following Kymberly Byers build of a LPB. I was intrigued by the process and decided to check out Cape Falcons Kayak. Being an avid RC airplane builder, I decided if I can build something that files, I can build something that floats. Next thing I knew I had ordered the plans for an F1 and building course. So now begins the adventure of building my F1 named “Tim”.

Jan. 20, 2022

I’ve been working on my F1 and got a lot done today. Still have 1 more deck beam to make and mortises for the deck beams. Let the fun begin.

Jan 23, 2022

Today was a productive day on the F1 as compared to yesterday. I got hung up on symmetry and why I could get my ends to meet evenly. After a text or two with Brian, he got me straightened out, I was able to kerf the ends, lash them, and then peg them. Making progress.

Jan 28, 2022

Yesterday was a learning experience in building my F1. Seems like it was two steps forward and at least 5 steps back. It also pays to review the process on making your deck beam tendons before you start. I managed to place deck beam 1 with a beam I should have used for beam 2 or 3. I used my special stick 1 incorrectly, measured to the outside instead of the inside, resulting in deck beams 1 and 2 being 3/8″ too wide. I did manage to force them in place so I could discover my mistake. A few texts later with Brian, he suggested in a nice way what I may have done wrong, and I was back in business. Final results, deck beams 1 and 2 correctly installed and I had to make a new deck beam 3 for later installation. My advice, watch the videos again on how to make the mortises and tendons before you start to work. It sure would have saved me a day’s worth of work.

Jan 31, 2022

I got some work done on my F1 whom I’ve named “Tim”. Tim was a good friend of mine who we recently lost to illness. Tim was the driving force behind “King’s Witness” which spread the Gospel through 5 simple symbols. I wanted to honor his work and try to carry on with his legacy. So, today I got all the deck beams pegged in place. It may not seem like much, but with that done I was able to remove all forms and straps. Looks a lot more like a kayak now. Tomorrow it’s on to planing the gunwales and getting ready for the ribs.

Feb 1, 2022

Got the ends planed and the steam box built for the ribs. I had some spare MDX laying around and is used it for the top and bottom. I used a vinyl tablecloth as a protective layer for the MDX. I ripped a 2×6 for the spacer wood.

The other day someone posted on “Skin-on-Frame Kayak Builders” FB page about Wally and Beaver Cleaver building a skin-on-frame kayak. I found the episode and thought Brian may get a kick out of seeing it. To stay true to the original design you must use tablecloths for your covering.

Feb 2, 2022

Today I was able to round the primary and secondary stringers and keel of my F1. I used a “Slickplane” to round them. It’s a great little device. I also cut the rolling bevels on the primary stringers using my power planer. It was a learning experience and thanks to Brian for showing us how on his videos. I was also able to capture “Tim” hanging out in the garage while I was working.

Feb 12, 2022

Back on my F1 build today. We spent most of this week at Universal Studios in Fla and visited Moes Tavern while there. I got my white oak ribs from J.W. Swan and Sons, and they are very nice. I measured the ribs to fit the size of the kayak I’m building and then rounded the edges slightly. I then cut the ribs to length, thinned the ends, and rounded the ends slightly. It’s starting to look more and more like a kayak every day. Next will be steam bending the ribs.

Feb 13, 2022

As they say, “It’s the little things that count”. I spent part of the day modifying my steam box and making my winding sticks for lashing the keel and stringers with artificial sinew. I setup my steam box bending area and took the steam box apart and coated the inside top with Kilz to make it waterproof, the bottom is covered with an old vinyl tablecloth. I also trimmed the midway support dowel down some so it would be easier to get the ribs in and out. I’m using an old clothes/curtain steamer for my steam generator and did a test run, and it works great. I’ve got to do a test run with it to see how long to steam my ribs to make them bendable. Brian suggests 7 minutes. We’ll see.

UPDATE: The Kilz and the steam didn’t like each other. The Kilz got sticky, so I took the top off and flipped it over and did a test run. Much better now. I’m not sure how long the MDX will stand up to the steam, but I’m hoping long enough to get 20 ribs bent. I did steam a test rib and it looks like 7 minutes will work. Hope to start bending Weds or Thursday.

Feb 17, 2022

Today was a very productive day working on my F1. I got all the ribs bent and in place. I only crack one and had to make a replacement for it. I then pegged a couple of them in place as recommended. Next, I lashed the keel to the ribs and the stems to the keel and the gunwales. To close the day, I clamped the stringers in place. I ran out of steam, I was pooped, and will get back to lashing the stringers on the ribs and stems tomorrow.

Feb 19, 2022

I didn’t get much done today because we went to Sierra Nevada’s Taproom near Asheville, NC to visit with our daughter and granddaughter. I was able to peg the bow and stern stems and make shims for where my stringers and ribs weren’t meeting in a few places. Brain suggests making them a little loose, so you won’t pass the distortion on to the next rib. I hope to get the stingers lashed on tomorrow after church.

Feb 20, 2022

This build has been such fun for me! I used to build RC airplanes from kits and scratch, but that all changed when they started making premade kits. Basically, you just assembled them. This has brought back the passion I had when I was building. Would I build another one, in a minute! Already thinking about what to build next.

Today I got the stringers lashed on to the ribs and stern and bow stems. Next is secondary stringers and other miscellaneous items.

Feb 21, 2022

A few more items off the build list today. I added blocks to the stern and bow stems. They will later be shaped to give some nice lines to the bow and stern when covered with fabric. I also got the secondary stringers glued on and some supports put in place for the rear deck beams. They will come out after the boat is covered.

Feb 22, 2022

Got the pocket mortise cut for the top deck stringer, shaped the bow and stern stems, and lashed the top deck stringer down. Looking more and more like a kayak every day.

Feb 23, 2022

So close to the end, next is to clean up the frame and then apply oil to it. I was able to reenforce the keel at the bow and stern. Attach the SLIDELOCK foot brace tracks, shape and peg the aft deck beam stringers and repair a knot hole in the frame. The stringers were made of oak that I cut down to the proper size. I next used my planer to remove material and then shaped them with my handy Dremel tool. All and all a good day. Tomorrow will either be the oil day or a kayak trip. Kinda leaning towards kayaking.

Feb 24, 2022

Got the deck line holes drilled and the kayak oiled with Minwax Helmsman Teak Oil. Waiting for the fabric which won’t be here until next week unfortunately.

March 6, 2022

My 840 X-TRA Tuff Ballistic Nylon fabric and coating arrived Friday while I was out of town. Yesterday I went to a Clemson Womens softball game. Today after church, I spent a few minutes finding center of the fabric and draped it over the frame. Tomorrow I’ll start the sewing process. I included a photo of my memorial to my friend Tim Roberson who I named the kayak after.

March 7, 2022

Today I learned to sew! Before I sewed the fabric on, I weighed the frame. It came in at 22 lbs. I got the fabric sown on the bow and stern. To make cutting the fabric easier, I bought a hot knife. It was money well spent. Make the cuts easy and gives you a nice straight cut and smooth edges to work with. No loose strings to deal with. After sowing the stern, you pull the fabric forward and then sow the bow and make a pocket. Next you pull the fabric back and stretch it over the frame. Makes it nice and tight. I then pinned the fabric down the keel so it can be flipped over and so I can begin lacing the top and then sew it. New skills are great!

March 8, 2022

Today’s report! I cut the fabric to fit the top of the kayak and then laced it up to remove any slack in the fabric. I was amazed how tight you could pull the fabric without tearing a stitch out. My next task will be sewing the top of the fabric tomorrow. I took a few pictures of the inside of the kayak before sewing it up to show the beauty of the frame.

March 9 ,2022

Got the fabric all stitched in place today. I first had to trim some excess fabric before I could start. again, hot knife to the rescue. I first stitched the stern and then moved to the bow. Tomorrow, I hope to get the coaming stitched on. Frame and fabric weighed in at 25 lbs. Fabric added 3 lbs.

March 10, 2022

Got the coaming stitched on today. I needed a 1 1/2″ overlap to sow the coaming on with, so I made a jig to mark with, thanks to Brian for showing us how. Once the fabric was cut, it was time to sew the coaming on. 26 lbs. Next up, dyeing the fabric. The weather is supposed to be colder, so I may have to wait a day or two.

March 11, 2022

Got the F1 stained/colored today. I went with the acid stain dye. I watched Brian’s video about the different acid dye colors and how UV affects them and decided on the “Sweet Potato” color for its looks and longevity. Biggest problem I have with it, is all I can smell is vinegar. LOL

March 12, 2022

Today was prep day to get ready to apply the polyurethane coating. I watched Brian’s videos several times and made my notes and gathered all my supplies. Next, I masked off the deck to prevent runs on it while coating the bottom. Hopefully I’ll get to start the coating tomorrow. Prince duck even showed up to check out his new ride.

March 13, 2022

Today I coated the F1 with the urethane coating. I have worked with resins and multicomponent paints for years, so I really wasn’t expecting anything out of the ordinary. Biggest challenge I faced was flipping the kayak over so I could also do the deck. I placed 3 sheetrock screws in the bottom and flipped it over to sit it on. I put 3 coats on the bottom and 2 coats on the deck. Took 5 hrs to complete. Now to sit here and watch it dry. LOL

March 14, 2022

I added the liquid keel strip today after talking with Brian. It was easy to do but has its challenges. To do it you mix 1 part A and 2 parts B, then you allow it to sit and thicken slightly. My room temp was 66 and it took 38 minutes for it to thicken up. I checked the goop’s temp when it started thickening and it was 93. Working quickly, I applied the goop and had a keel strip. UPDATE: I weighed the kayak and with 3 coats top and bottom and the keel strip, it weighs 29 lbs.

March 16, 2022

Worked on the deck lines today while it was raining. I took yesterday off and went kayaking with some friends on Lake Jocassee in Upstate SC. First thing I did was pull the leather strips thru 1/4″ hole and then a 3/16″ hole. It helps stretch the leather and narrow it down a little. Then I located my predrilled holes in the gunwales and used a large nail to burn holes in the fabric. It was a bit of a stressful time to do that to my kayak, but it worked out well. I then pulled the leather thru the gunwales and the deck toggles. I secured the lines with knots and moved on to the bow and stern grab loops. Next up will be fitting the backband and seat. I’m so close I can smell the ocean.

March 17, 2022

After performing some household chores, I installed the back band. I clapped the back band in place and measured to make sure it was centered. Then I marked the coaming and drilled the holes for the bolts. I followed Brian’s recommendation and used a 3/16″ shim to properly space the bolt head and it worked perfectly. Once the back band was bolted down, I used cord to prevent it from dropping too low. Waiting for the seat to arrive. While waiting I’m going to put on some perimeter deck lines.

March 18, 2022

I added the seat mat and the seat I got from Guillemot Kayaks. The mat is a Therm-O-Rest Ridgecrest. I’m sure the mat would work for others, but I felt that I needed something with some support for my legs. I was very impressed with the seat. Hardly any added weight. The rest of the mat is used to rest your feet on. I still need to cut a hole in it for my bilge pump.

UPDATE: I’m not going to be able to use the seat I got. It makes me sit very high in the cockpit and will make the kayak tippy for sure. The only way to use it would be to heavily modify it and I hate to ruin a very nice seat. Brian also reached out to me and suggested to make the cloth seat and use it and the mat together. Thanks to Brian for reaching out.

March 22, 2022

After trying the aftermarket seat and finding out that it will have me sitting to high, and cause the kayak to be tippy, and with input from Brian, I decided to make the seat for it. I used leftover cloth for the seat and some carbon fiber tubing that I had for the attachment hangers. You slide the tubing with the seat on it behind the ribs on top of a stringer. I’ll find out how it works in a couple weeks after my knee surgery heals.

March 23, 2022

The maiden of the F1 will have to wait for a couple of weeks. I had my right knee scoped today to repair some extensive damage to my meniscus and outside compartment that has arthritis. I got this space age cooling device on my knee and some pumps for both legs to prevent DVT and to help promote healing. I’m going to have to wait until the stitches are out and wounds healed before I can hit the water. Timings everything right. LOL

March 29, 2022

What do you do while you’re waiting to get your stitches out from the result of having your knee scoped? You put a brass rub rail on your new F1 build. Some of the launch sites that I use have rough concrete ramps with shoulders so the boat trailers can’t back off of them to the side. I got to thinking about wear on the bottom, so I decided to at least protect the bow. The stern already had a rub strip. I ordered the half oval brass from Online Metals. Sloped the front some, drilled 4 holes, countersunk them, put Aquaseal in the holes, and mounted it. One more week before I get my stitches out.

March 30, 2022

Being out with stitches and having a new kayak to test is driving me crazy. So crazy that I made a Greenland Throwing Board, Norsaq to go with it. I had some left-over cedar, so here’s my attempt. The board is 18″ long, 3 1/2″ at the hand end, 1 3/4″ at the other end and 3/4″ thick. I got my measurements from Ancient Projects: Arctic Regions – from Siberia to Alaska. I’m going to coat it with tung oil. I have another project to complete. Stay tuned.

Mar. 31, 2022

I like to keep busy, so today I started my balance board build for kayaking. The plans came from Christopher Crowhurst and William Nash and can be downloaded as a PDF. I’ve got it all cut out and will stain and assemble it tomorrow. I know I have a problem; I’m working on it. LOL

UPDATE: Board is finished. Waiting on tung oil to dry.

Apr 3, 2022

I added the perimeter lines on the F1 today. I used a gold 3/16″ +/- 750 lbs. paracord for the lines. I think it looks pretty good. I get the stitches out of my knee Thursday and plan on the maiden of the F1 for Friday, weather permitting. Photos and impression to come.

UPDATE: We had rain heavy today, Apr 5, and I went out to the garage to get ready to start another project and I checked on my F1. I was shocked to find my perimeter cord looked like spaghetti. It was very loose and stretchy. To say I was disappointed is an understatement. Thank goodness I had ordered some 5mm Golberg Premium Polyester Accessory Cord. I’ll be replacing the paracord tomorrow.

Apr 12, 2022

Today was the day! I finally got to maiden my F1. I went to my favorite lake, Lake Jocassee for the occasion. All I can say is I’m impressed. It tracked true and will turn on a dime. I seemed to glide over the water and when I got home, I checked my GPS and found my average traveling speed to be 3.8 mph without trying really hard. As a comparison, in my Cetus I average 3.3 mph. It was a short 2.5-mile paddle due to the wind getting up, but I’m really happy. I even got checked out by a Canada Goose who gave me “wings up”. Can’t wait to cover more miles with my F1.

Apr 13, 2022

Follow up thoughts on my build: I started my build after I had seen several posts by Kymberly Byers building the Cape Falcon LPB and was hooked the moment I it. I found Cape Falcon’s website and the rest is history as they say. I ordered all my supplies, and the building began. Brian’s videos are the key to the build. It’s like you’re in one of his workshops. I can’t say enough about them. The F1 is a wonderful kayak and I’m so glad I built it. It’s robust and light weight, and as others have said it glides across the water and paddles effortlessly. It was as comfortable as Brian said it would be even though I was a bit skeptical at first. I’ve got a Redfish seat in my P&H Cetus and the seating setup that is used in the F1 is as comfortable as it is. I’m looking forward to many miles with my new “best friend”. Thanks again to Brian for his videos and his time to answer my questions and offer support along the way.

Apr 18, 2022

After the maiden of my F1, I decided it was time to upgrade carrier system on my trailer, it needed something softer to ride on. My current carrier system was Malone SeaWing kayak carrier. It worked well, but then I saw a post from a fellow kayaker, and they were using the Goodboy Paddlesports “Classic V-Bar” system. After some research, I ordered a pair to replace the Malone’s. This system is so nice and well built. It has padded arms, you use bungie cords to strap your kayak down, and cam straps as added insurance. Check them out if you’re looking for a new way to carry your kayak.


View posts by Bobby
Seneca, SC

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