Gardennorm

Member

Registered: 1 Feb 2013

Posts: 12

Night Heron stitch and glue

Hi everyone!
To keep me out of mischief I thought it would be a good idea to build a sea kayak!
After looking through the various plans I short listed the Night Heron, Petrel and the Pax 20, but as this was my first attempt a building a kayak and also living on a Greek island I thought it best to stick to the simpler method of stitch and glue so I plumped for the Night heron.
I wanted to do everything so just ordered the plans and this is where the problems started.
Greece may have crystal clear waters and beautiful weather but finding things that we mostly take for granted in the UK can be a problem!
4mm marine ply! sorry the thinnest marine ply is 6mm! So do I build a rather heave kayak or opt for 4mm general purpose ply? I went the the 4mm with the thought process that it will be completely protected with epoxy and paint, time will tell if this is a mistake.
After getting the ply, which was quite badly stained, Ive opted to finish the kayak with a gel coat.
Next problem was the first lot of epoxy was not strong enough so my scarf joints fell apart!!
Now got a high quality epoxy, scarfs holding fine.
In my excitement I did not take photos of the initial stages, so my pics start at the stitching and gluing stage, very exciting seeing these carefully cut, planned and sanded strips of ply suddenly turn into a kayak shape!

Ill post more pics as the build moves on.
Fiberglassing and making hatches at the moment.

Gardennorm

Member

Registered: 1 Feb 2013

Posts: 12

Re: Night Heron stitch and glue

A few more pics of the cockpit coaming and the rear hatch rings

Gardennorm

Member

Registered: 1 Feb 2013

Posts: 12

Re: Night Heron stitch and glue

Finally got to the enjoyable stage of joining the deck to the hull, its great to see the shape of my kayak!
I decided to stitch so that I can get a tight seal and as this is my first attempt at building a kayak the stitches will help to pull the surfaces together better than tape.

Richard

Member

From: East Sussex

Registered: 7 Jun 2011

Posts: 75

Re: Night Heron stitch and glue

It looks fantastic well done

---

Canoe & Kayak Owner

beaker

Member

Registered: 9 Oct 2011

Posts: 81

Re: Night Heron stitch and glue

Very nice shape there. Are those plywood twist lock hatches? I haven't seen those before.

Gardennorm

Member

Registered: 1 Feb 2013

Posts: 12

Re: Night Heron stitch and glue

Thanks!
I really like the shape too, yes they are twist lock hatches, theres quite a bit of work involved in making them but I do like the look of them in photos ive seen of the finished boat.

Gardennorm

Member

Registered: 1 Feb 2013

Posts: 12

Re: Night Heron stitch and glue

Here is the inside of the twist lock hatch.

Gardennorm

Member

Registered: 1 Feb 2013

Posts: 12

Re: Night Heron stitch and glue

Primer now being applied, Hopefully not to long till i find out if it floats!!!

Gardennorm

Member

Registered: 1 Feb 2013

Posts: 12

Re: Night Heron stitch and glue

Final stages now, its taken much longer than I expected but its been very enjoyable, already thinking of the next one!
Painting finally finished.

For the seat I made a concrete mold by building a box the same size as the hull and filling a bag with concrete, then sitting in it, I gave it a few coats of paint then covered it with cling film to be sure it would release and added fiberglass.
The deck elastics being fitted temporarily.

Gardennorm

Member

Registered: 1 Feb 2013

Posts: 12

Re: Night Heron stitch and glue

The finished kayak.
It perform beautifully, the hard chines making it easy to control by edging, its also quick and very comfortable, I love it!!

beaker

Member

Registered: 9 Oct 2011

Posts: 81

Re: Night Heron stitch and glue

Nice boat, fantastic location!

Paul

Employee

From: Gatebeck Cumbria

Registered: 4 Aug 2011

Posts: 131

Re: Night Heron stitch and glue

Your boat does look superb and it is good to hear that you are pleased with it.  Thank you for taking us through the build.

Jason Gillingham

Member

Registered: 1 Feb 2013

Posts: 31

Re: Night Heron stitch and glue

Great photos