Free

A4
Building guide and drawings
Table of contents

Licence 3
Hydrostatics 3
Free 4
Material list 5
Ply layots 6
Drawing of curwed lines 7
Drawings to ply sheets 8-21
Joining of side- and bottom panels 22
Bulkhead 1 23
Bulkhead 2 25
Assembly 27
Optional bulkhead 3 27
Gunwale stringers 28
Assembly sequence 29
Support for footbraces 29
Top gunwale stringers 30
Decks 31
Cockpit ring 32
Finishing 32
Backrest 33
Footbraces 35
Gluing hatches 36
Optional hatch recess 36
Cockpit ring alternative 2 38
Rudder 39
Footbraces with steering pedals 40

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LICENCE

Plans contain two parts, building guide and printable 1:1 cardboard templates.

Plans of the free are free! Build the free – be free!

Free plans doesn’t mean that boat is not good - I call it performance expedition kayak.

Hydrostatics :

Design displacement : 111 kg ( 245 lbs )

Draft :108mm ( 4 1/4” )
Waterline Beam : 504mm ( 19 7/8” )
Waterline length : 4315mm ( 14` 1 7/8” )
Block coefficient :0,48
Prismatic coefficient : 0,54
Wetted surface : 1,8 m2 ( 19,76 ft2 )

3
Free

Length 4840 ( 15´ 10 1/2" )

Beam 528 ( 20 3/4")

This boat is designed for day- and weekend trips. Longer trips are also possible if packing light. Design
displacement is 111 kg /245 lbs( including boats weight ). I tried to design a kayak which is fast to build
and good to paddle. This is actually fourth evolution of it and I really like how it performs. If you never
paddled a kayak before, this may feel a bit tippy at first.

This boat can be built quickly and cheap. Flat decks makes it easy to fasten hatches directly to decks, but
there are still option for recess hatches. Cockpit ring can be built quickly from 4mm ply, but its more
nicely done from extra 9mm sheet.

On conditions where boat wants to turn against wind, just lean boat constantly against wind to balance
the situation. If you like rudder steering, there are removable rudder and steering designs at the end of
plans. I have tested that they work, but it is of course possible that they might jam – so test rudder
carefully!

Check ply sheet dimensions! I have observed that all sheets are not actually 1220*2440. That is why
register lines on ply sheet 1 and 2 are divided differently.

Search from web for foamed plastic. I use it as seat, backrest padding - Or bought cheap camping matt
and glue it to several layers when needed.

Learn to use epoxy correctly. Read manufacturer instructions or search on web, how to make wet to wet
coatings and how to dewax cured epoxy. And remember to use safety equipment while handling epoxy!

Build and use this boat with your own risk. It is very small home built boat and could be damaged by
faulty gluing or material failure. Make sure that you are aware of proper and safe use of all materials –
read manufacturer’s directions.
Learn to use the boat in safe waters and conditions. First keep land close until you get used the boat. Use
life jackets and learn their proper use. Don´t allow children to play with boat without supervision.

More informations of my boats :

www.kaamosboats.com

My other boat plans :

http://www.duckworksbbs.com/plans/korhonen/index.htm

Plans, hardware and great stories can be found in:

http://www.duckworksbbs.com/

Send photos of your building and paddling adventures!

[email protected]

Go paddling and have fun!

( Even plans are free, I still own copyrights )

Perttu

4
Material list
List is made according standart lumber sizes found where I live. Standarts can vary between countries.
If lumber size shown on list cant be found in your local store, it has to be cut from another size of lumber.

Plywood 1220 * 2440 ( 4´x 8` ) Exterio

r or Marine
Thickness Number
4mm ( , 1/8" ) 3`
9mm ( 3/8" ) ( optional for cockpit ring alternative 2 ) half sheet 1220*1220
( 4´x4`)

Lumber
metric ( imperial )
Use Longest parts Length

19x19mm (3/4 x 3/4 ) gunwale stringers, framing 4880 15000mm

( 16` ) ( 49` )

19*45mm ( 3/4 x 1 3/4 ) bulkheads , framing 550mm 2000mm

( 22" ) ( 9` )

19*64mm ( 3/4 x 2 1/2 ) bulkheads, footbrace, temp. Frames 700mm 6250mm

( 28" ) ( 21` )

25*32mm ( 1 x 1 ¼ ) footbrace 330mm 330mm

( 13”) ( 13 ”)
32*64mm ( 1 1/4 x 2 1/2 ) footbrace 330mm 350
( 13”) ( 13 ”)
Other materials :

Glass tape 50mm wide – 60 meters ( ca. 160g/m2 )

2” 197` ( ca. 6oz approx )

Glass cloth for laminating backrest – one peace...

( or glass tape )

Camping matt for seat, backrest, knee supports - one roll

saddles 2
ladderlocks 2
20mm strap 3 meters ( 10`)
clamcleat 1
3mm rope for footbraces 2 meters ( 7`)
+ 6mm threated rod + knots
+ some stainless screws

Glue Epoxy + microballoons or urethane glue and polyester resin for glassing
polymer glue for fastening hatches, paddings etc.

2 kayak hatches

( rudder fittings are not included in material list )

5
6
Drawing of curved Lines

ply sheet
register lines

te
mpla
ard te
cardbo

pen

i bl e batten
fle x

nail

Draw register lines to ply

Mark dimensions to register lines positions
Hit nails to marks
Push flexible batten to nails
Draw curve according batten
Use 1:1 cardboard templates where possible
On side panels, curve direction changes (on gunwale ). Don´t try to push batten over those marks - move
batten and draw one side at a time.

7
Drawings to ply sheets

8
9
 Draw top shape when fitting ring to boat

10
11
12
13
14
15
16
17
Bulkheads - see next pages

18
Bulkhead 1
( hmm - enough dimensions? )

19
Bulkhead 2

20
cockpit ring alternative 1
Ring is ca.10mm larger than opening in deck.
Trim deck to match ring after gluing.
Use templates 21-25 to draw ring.

21
Joining side- and bottom panels

front side panel back side panel

detail view from joint

front side panel Nail sidepanel to thick board.

(cover with package tape, to prevent
gluing panel to board )

nails

nails

back side panel

Nail another sidepanel to board.

Apply glue between edges.

nails joiner nails

Apply glue to joiner. ( 120mm wide ply )

Place joiner to seam and hit nails to corners.
( on side panel, leave 19mm gap for gunwale stringers.
On bottom panels - let joiner go over panels on both edges )
Hold joiner on place with nails.
Place thick board over joiner
( cover with tape )

Clamp and let glue cure.

After glue is cured - cut joiner according
panels and plane joiners bottom edge close to zero.

22
Bulkhead 1
r s
str inge
lots for
cut s

0
19*7

bow
d from
we
vie

ply

s tern
e d from
vi e w

23
24
Bulkhead 2

er s
r s t ringg
o
lots f
cut s

8)
9*3
r1
(o
*45
19

n
s ter
fr om
d
we
vie

ply

t
k res
bac
for
rts
su ppo

w
m bo
d fro
viewe

25
side view

26
 Assembly
First stitch bottom parts together
( drill holes near ply edge - use plastic cable zip ties or copper wire )
bow
Next stitch bulkheads to bottoms

go -
les at one
stern n`t drill ho
ly. Do
semb
ot he as
ides t
s, p lace s
m
botto nds.
tit ch ed to rds both e
es wa
ds ar ve to
r bu lkhea le and mo bow
Afte midd
from
start

stern

Turn boat around. Check that rocker looks smooth. ( Small error is ok. ) Near stern is biggest
possibility that rocker don`t want to go straight. If so : make BLK3 to guide boat to right shape.
If you have been accurate with panels there should not be need for blk3.

Optional bulkhead 3

27
 Gunwale stringers :

Top part goes only to side decks positions

( can be glued later ) Length ca.2230. ( to middle )

Lower stringers lengths are ca 4880. Taper both ends

from inside face, so they fit near both ends.

nds
cks e
e de
he re sid
o int w
ear p
s e dge n
el
epan
e ac h sid ws.
r e
dont y scr
e s t i rgers temporar
wal ith
Gunn tringers w
s
Glue

!
fa ces!
N SI DE!
ply I
en
b etwe
nsi ons
dime
t
p boa
to kee
s
at ten
19b
19*
ary
mpor
e te
lac
edp
eed
- if n
ons g. es!!
nsi lassin E! fac
e n ply INSID
dim g etwee
se hile sion b
k the ape w dimen
ec h
Ch ight s
r
on

Optional support for rudder.

Fill gab between stringers from ca.200mm from stern.

28
 Assembly sequence
1. tighten stitches and check that parts fit nicely -
ensure that bulkheads are not twisted.
2. apply epoxy fillet to inside seams - let fillet harden a bit, so that it doesnt stick to finger.
( apply fillet also to bulkheads seams )
3. place glass tape over epoxy fillet and spread epoxy over tape - Let cure
4. remove stitches, putty outside seams and sand after putty is cured.
5. glass outside seams

ply

epoxy fillet glass tape

plastic cable zip ties
or copper wire
cut wires

drill holes to ply glass tape

!
heads stape )
e a ms. t w e e n bulk g la s
side s dle be rom 100mm
s s in m id
Gla rs to yer f
o laye top la
Put tw ave make
uh
( if yo

bo
w Support for footbraces

Use these dimensions as guide and

modify bottom shape according your boat.

Fasten with temporary screws thru bottom.

back
front

29
Turn boat around :
- remove stitches
- putty seams ( let cure )
- sand
- glass seams ( red )

Gunwale top stringers :

Top part goes only to side decks positions. Between marks drawn on side panels.
Length ca.2230mm.

Plane stringers to zero ca 222mm from back

and ca.525mm on front.

30
 Decks
er
geth
k to
dec
iddle
an dm
front
ts titch
Firs

ne
bly pla
sse
m and
to a bow
ec ks n ear
ed end
sid ks
titch dec
xt s sid
e
Ne e
her
tw
oin
lly p
ar efu
eckc .
Ch tb end
s. ly".
d eck ll tigh ice
nst sm
a it n
agai n ck s "f
s fit
is eve t de
ger ere o th
a
s trin if th s
h ow rors d ed,
eck mir ded
. nee .
t. C
h ily nee as ber
eas ere ws m
boa poi
nt wh scr
e 0 lu
s to at rs ny 19*
9 es
deck . Th nge ma m fr am
Lift oth stri es
o
r fro cr oss
sm
o
lan
e us *64
o
rs p r s- 6 ) . e s to
nge nd g e r 1 g e s
fram
stri ya trin 5o din am
s aw
a
r y to s ks. 1 9*4 ll y bon oss fr s ide
k r ew
dec por
a dec from ame. identa ts to c scr
Lift s tem u n der e cks s fr a c c p a r o n´t
k d s s. D
dec shap
e
ove
r cro event w side eck
r ew t s es k as p r c re o d
S c o a ra m e c t o ts t g!
wb ry f to d mes tha es sin
Dra p ora m ber all fra after w fram r g las
tem ne lu e on s and cre e fo
a s ten w o t a p c k a t to s s pac
e e o
F
st s
cr
ckin
g
s to
d b ave
- fir se pa e part s from ! e s - le
k t g
( u w sid dec boa pe
d
s c re m ove c k to cks to
e a
- d, r ed
b
ed
e
n eede c rew ar sid
- If s e
are sn
e c ks c r ew
il d lace s
unt tp
on´
-D

d. ms .
aroun d glass sea
tu r n them s a n
oat an
d eam
hed s
ck s from b t over stitc
Lift de epoxy fille
d
Sprea

31
 Cockpit ring
Cockpit ring is made from 3 layers of 9mm ply. ( See also option of ring made from 4mm ply )
Two bottom layers are similar,and top layer is bit larger from outside. You can save ply by making just bottom ring
from one piece and glue middle layer from left over piece and route or saw them according bottom ring.

position ).
on cockpits
ry screws (
it w ith some tempora
fast en
to boat and
Place deck

n
keep ring o
fr om insi d e to ring to o le s )
rews pivot h
mporary sc remember
d e ck s. U se some te s fr o m ri n g thru ply -
it ring to some long
screw
Glue cockp ( or just use ards deck.
o si tio n re ss ing ring tow it position.
correct p
r te m p sc re ws ) fo r p
in t in si de fa ces.
a n d p a in t only cockp
s(o d pa uch )
Use clamp oxy coat an ish them m
o ve d e ck s, sand, ep ra g e s ( do n´t even fin
Re m ack sto
front and b
I just epoxy

Glue deck assembly to boat. Use temporary screws thru decks to stringers. Use thickened epoxy as putty
on inside to fill possible gaps. Glue also short back deck to its place.
- trim extra ply away
- putty gabs
- sand
- glass ( red seams )

Finishing
Sand glassed seams gently, then apply putty, sand ..do epoxy coating, sand....and finally do the painting.
Remember to dewax and sand epoxy before painting. The way I usually do epoxy coating is not official,
but it ́s easy and epoxy-saving method. Pour epoxy to ply face - spread it with rubber scraper -
only so thin layer that surface veneer gets temporarily wet. It will soak epoxy, but let it be so.
Wipe out all leftover epoxy and let it dry over night. The ply surface has now soaked the epoxy and
surface is easy to sand smooth with sandpaper - not with sander! Apply another coat same way
as described. This method won ́t give thick epoxy coat, but you can get even base for painting -
with minimal sanding - even thin layer of epoxy is better than just paint.
If you want more durable epoxy coat, apply epoxy with wet to wet method.
I have the habit to sand thick epoxy coats through wood, because the surface is uneven after epoxy is cured.

32
Backrest

ply

6mm 20mm strap

treate
d rod

20mm strap

back
( car rest ply
d 4m
300* board te m
165m mpla
m te 31
)

Laminating backrest ply

Cut ply a bit larger than backrest. Tension ply with rope. Right amount is a bit guess - it
depends from glass thickness etc. and after glassing lamination opens a bit, so make it a bit more
curved than needed. ( Less curved backrest is probably better choice. )
I made ca.30mm tension and I think it was a bit too little.

Glass inside face - let cure and cut ply to shape.

33
 Cut right angle to frames according ply.
( cut angle first to oversize lumber and make rest shaping after that )
Glue frames to ply. Drill pivot holes and be very carefully not to split frames.
Use clamps and only one screw for holding frame on place.

Frames - see template 32

cut angle according back rest
after laminating

side
view

. fasten clamleat for footbraces

addle
a p f r om s trap.
ort st
r wer s
to sh omes to lo ports
we d ee sup
- se ck c g to kn
r lock der lo glue paddin
ladde er side lad
th
On o
saddle
dle. est.
d sad backr
n
rou " from
t a r ps u gh
t o s ar en o
s f
loop dle "
Sew en sad
t
Fas
glu sea
ep
add t:p
ing iece
to b of c
ack amp
res ing
t mat
t etc
.

34
Footbraces

Check that there is enough

space for camcleat.

side view

8mm ply
top view

35
 Gluing hatches
ed.
e re need
m e r glu screws a
l y o
e po s-n
e ck s. Us e clamp
to d . Us
tc h rings th tape )
ha wi
Glue ct decks
t e
( pro

Optional hatch recess

( for kayak sport - KS round hatch 24 )

ly
mp
4m
9mm ply

Drill pilot holes thru both parts with a bit smaller drill
than nails diameter are. Apply glue, drill holes and
hit nails as you proceed.
Use thin nails that come thru 9mm ply ring.

When you reach 360 degrees -

mark edge position an cut side part.

Side view - bottom can be cut to 90 degrees or to 13 degrees.

36
Join side with clip of plywood.
After glue has cured - remove nails and sand joiner as thin as you dear.

y top.
k e n e d epox x tr a p ly from
ic e
read th ed trim
to d e ck. Sp epoxy is cur
cess t. After
atch re all fille
Glue h a s s m
er side
to und

.
eded
e r s if ne
g
strin .
o at - trip to sides
t o b s l ot s
deck aped
Glue all V sh
m
Cut s

lots
r cover s
wood fo
ces of ply
glu e pie

-trim extra
- sand
- glass & sand

37
Cockpit ring alternative 2

Cut ring first a bit larger than shown on plans.

Fasten small blocks to deck with screws. Cover blocks with package tape!
Fasten cockpit ring first from back with temporary screws to BLK2s top frame. Push ring towards deck
and screw it to temporary blocks on deck. Mark position where ring will be cut to final length.
Draw rings top shape : place a piece of ca. 9mm thin piece of wood under pencil.
Remove ring - cut top edge and fasten it again to same position.
Glue ring to deck. Use epoxy fillet between temp blocks. DONT GLUE ring to BKL2 yet!!

Remove deck - trim ring bottom edge according deck. Putty - sand small radius to join
and glass seam.

Glue decks to boat . Remove temporary blocks and make final fillet around ring. Glass outside seams.

Glassing ring :
Cut small cuts to glass tape or it would not
bend nicely. After glassing - apply putty and
sand seams smooth.

Finish ring with rubber U moulding .

( used on car body parts etc. )

38
Rudder rudderbox
8mm ply
( dimensions on cardboard templates 33-35 )
b oat
der to
s t e n rud nuts e
F a ing guid
with w rope

e
fram
pe ) m rope
)
mm ro
in g li n e ( 3
d d e r up ( 3m r ope )
steer ru
d o w n ( 3mm
rudder

e)
( 3m m rop rudder
g line 8mm
steerin

Fasten aluminium "hinge" to rudderbox with screws and polymer glue.

( aluminium must be painted or glue would not hold!)

e
clip of aluminium tub
t/ 6m m inn er dia
8mm ou

6mm threaded rod

e
clip of aluminium tub
6m m inn er dia.
8mm out /
( as hin ge )
8mm ply

6mm threaded rod 8mm ply

3
or
8mm ply

al
um 4m
9mm spacer

d in m
rudder 8mm - glue ropes

oo iu
m
lyw
oat ep
r t o b 6mm fra
m
de ue
rud ts. Gl t
s t en n u oa
Fa wing d to b
i t h d r o
w
ade
thre

e
clip of aluminium tub
er dia.
8mm out/ 6mm inn
( as hinge )

39
Footbraces with steering pedals

clamcleats for steering lines

40
small loops off flexible rope it
kp
c oc lock
b
ide en
on steering line

s ins ood
ine u w
in g l thr
er be
ste nd tu
be
clamcleat for red line

41
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