Building a KAHOLO 14' in a 16' garage!

Robpeek79 · 25 Jul 2012 10:37 am

Hello All,

I am very new to boat building and even newer to writing about it on this, or any, forum.

At the start of this project I decided to record the entire building process with my GroPro. It has been steadily taking pictures every 60 seconds. The aim is to put all the pictures together to create a fast forward video of the build.

A couple of weeks ago I received an much anticipated package from Fyne boats, my Kaholo 14. In truth I was expecting a bigger package but undeterred on I cracked on.

I only have a single garage and at the start of this build if was full of kit I was storing for a friend. Clearly I asked the kit to be moved as I needed the space.

Last edited by Robpeek79 (25 Jul 2012 9:08 pm)

Robpeek79 · 25 Jul 2012 11:22 am

Fibreglassing the underside of the deck

Robpeek79 · 25 Jul 2012 11:24 am

Wiring the SUP together was an exciting step, seeing the shape for the first time. I ended up taking rib 2 & 3 out to ajust the size to allow for the best fit.

Robpeek79 · 25 Jul 2012 11:25 am

The big levelling process before committing to the shape and glueing the seams!

Robpeek79 · 25 Jul 2012 11:27 am

Filleting, I found it easiest if I mix quite a lot of wood flour into the epoxy.

Robpeek79 · 25 Jul 2012 11:31 am

I decided to go with the 90 degree shape in the transom. I am really pleased with how it turned out.

Glueing and epoxying the interior.

The transom glued in place.

Robpeek79 · 25 Jul 2012 11:35 am

Planing the sheer clamps flat, a very satisfying step. It was very easy to hit the ribs with the plain!

Shaping the nose block. It was only just big enough so I had very little to take off.

Filleting the deck reinforcements and gluing the carrying handle blocks in.

Robpeek79 · 25 Jul 2012 11:39 am

Gluing the deck onto the hull was another very satisfying step. The board really comes alive.

I used a flush trim bit on a router to get the deck to size. This was a very quick and effective. I then ran round the board with a round over bit to get the edges to roughly the right shape. This was then followed up with a block plain and sandpaper.

Robpeek79 · 25 Jul 2012 11:42 am

Loads of sanding!!!! Firstly 90 them 120 and finally 240.

Glassing the hull

Robpeek79 · 25 Jul 2012 11:46 am

Sanding down the edges prior to glassing the deck.

Turing my favourite Hawaiian shirt into part of the design.

Again preparing for more glassing.

Robpeek79 · 25 Jul 2012 3:16 pm

Warm epoxy really does make all the difference!!!

I put my epoxy in the sun for a couple of hours and it got really hot. It was very nearly the consistency of water. This makes it very easy to apply, however because my garage was about 28 degrees today it was kicking off very fast. However this will reduce the re-coat time

Last edited by Robpeek79 (25 Jul 2012 9:13 pm)

Robpeek79 · 25 Jul 2012 3:21 pm

I decided this afternoon I would score the deck where the paint from the hull will end on the deck. I am not sure if this is a good idea but it is done now.

Robpeek79 · 25 Jul 2012 3:21 pm

First coat all done.

Robpeek79 · 26 Jul 2012 10:13 am

I have ended up with a very rough edge where the deck fibreglass is bonded to the sides. You can just about make it out below.

However, after a load of sanding it seams to be smoothing out. I did most of the sanding by hand as I did not want to sand to much with a machine.

Robpeek79 · 26 Jul 2012 1:46 pm

A big sanding session this morning in the sun.

A couple of days ago I drilled a small hole in the deck to release the partial pressures that occurs during the day. In the sun today a great deal of air escaped.

Rinsing after sanding.

Finally I glued the fins in place, I constructed a super crude jig to ensure they are position correctly and parallel to each other.

Leggy · 26 Jul 2012 3:25 pm

I like the transom. Is that your addition or does it come with the kit?

Robpeek79 · 26 Jul 2012 4:27 pm

Hi Leggy,

The kit comes with strips of cedar and pine (I think it is pine?). The manual points you in the direction of horizontal strips however it does also say you should use your imagination with the transom.

You could do something very complex but as this is my first build of anything like this I stuck with the right angles.

stanrich · 1 Aug 2012 7:46 pm

Nice job. I started my own pair of 12-6 Koholo's for the family last week here in California and also have a Kaholo Building Blog of the build. I have decided to make a rather radical change to the top deck by recessing a foot well into the design. (they did encourage us to make modifications didn't they )

I am interested in your additional comments on scribing the paint line and if this plan worked out as expected.

I really like your idea of using a favorite shirt for your pattern. I have a closet full of these and I just might do the same.

Robpeek79 · 3 Aug 2012 6:17 pm

Hi Stanrich,

Thanks for the chuck up. I am mightily impressed with your modifications! Now that I have my first build almost out of the way, I will defiantly consider modifying the next one for the wife. Also great blog. I will let you know how the scribe on the deck works out for me in the next couple of days as I will start painting and varnishing tomorrow.

Robpeek79 · 3 Aug 2012 6:30 pm

After a couple of quiet days in the garage, I spent the afternoon sanding my board. I am not sure exactly how smooth it all needs to be but it seems smooth to me? I will only know when I finish the painting and varnishing.

I was a little over enthusiastic with the epoxy when sticking the fins on and I spent an age sanding around the fins.

Finally I put a thin layer of epoxy over the deck and I am hoping I will be able to varnish over this tomorrow.

beaker · 3 Aug 2012 9:07 pm

Very very nice. I might be tempted to leave the epoxy a while to fully cure before you sand and varnish. You could always take it out before the varnish - not too much intense UV risk this weekend I think!

Robpeek79 · 4 Aug 2012 9:22 am

A quick session this morning whilst the wife is out!

This morning I coated the fins with epoxy, they have come out really nice.

Second I painted the hull with undercoat provided by fyne. It becomes immediately obvious after painting that any efects become very easy to see .

You can just about see the defects in the seam. I am hoping a couple of layers of undercoat and some sanding will level everything out.

Finally, I really like the score on the deck. It has made it very clear where the paint is going to end and varnish start.

Robpeek79 · 5 Aug 2012 9:04 pm

Managed to get a little time in the garage this afternoon. I managed to get through the final sanding done. I used a 240 grit wet and dry paper wit loads of water.

Second up for the day was a major war on the dust in my garage. I decided to not to clean all my tools and work benches but just to seal them with plastic dust sheets. I also covered the floor with water to reduce further the dust.

Finally, the first coat of varnish goes on the board.

Robpeek79 · 2 Sep 2012 8:47 pm

Finally after a month away I have finished the varnishing and painting of my Kaholo 14.

Overall I am very please with the finish although it is not perfect by any stretch of the imagination.

Just some finishing touches next weekend and a maiden voyage.

I am going to put a 8 inch hatch in the bow and I will use some trim tape around the Hawaiian shit on the deck. That is about it and I can not wait to give it a go.

Gardennorm · 1 Feb 2013 5:16 pm

Looks fantastic, I love the idea of adding your shirt under the fiberglass.

#1 25 Jul 2012 10:37 am

Building a KAHOLO 14' in a 16' garage!

#2 25 Jul 2012 11:22 am

Re: Building a KAHOLO 14' in a 16' garage!

#3 25 Jul 2012 11:24 am

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#4 25 Jul 2012 11:25 am

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#5 25 Jul 2012 11:27 am

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#6 25 Jul 2012 11:31 am

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#7 25 Jul 2012 11:35 am

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#8 25 Jul 2012 11:39 am

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#9 25 Jul 2012 11:42 am

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#10 25 Jul 2012 11:46 am

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#11 25 Jul 2012 3:16 pm

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#12 25 Jul 2012 3:21 pm

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#13 25 Jul 2012 3:21 pm

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#14 26 Jul 2012 10:13 am

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#15 26 Jul 2012 1:46 pm

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#16 26 Jul 2012 3:25 pm

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#17 26 Jul 2012 4:27 pm

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#18 1 Aug 2012 7:46 pm

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#19 3 Aug 2012 6:17 pm

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#20 3 Aug 2012 6:30 pm

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#21 3 Aug 2012 9:07 pm

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#22 4 Aug 2012 9:22 am

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#23 5 Aug 2012 9:04 pm

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#24 2 Sep 2012 8:47 pm

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#25 1 Feb 2013 5:16 pm

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