DIY Kevlar Canoes & Kayaks

The same properties that make Kevlar a popular fabric for bulletproof vests make it an excellent choice for constructing canoes or kayaks. Kevlar is stiff, lightweight and extremely tough. Boats made from Kevlar can often withstand an impact with a rock or other solid object far better than boats made from fiberglass or carbon fiber. Not surprisingly, this strength comes at a price. Kevlar is also far more expensive than fiberglass or carbon fiber and costs anywhere from $20 to $40 per yard. Its only other drawback is that its tough nature makes it difficult to sand and cut in the event that repairs do need to be made.

Things You'll Need

  • Canoe or kayak mold
  • Mold release wax
  • Fiberglass
  • Resin
  • Kevlar fabric
  • Epoxy
  • Hardener
  • Wood stripping for gunwales and decking
  • Glue
  • Clamps
  • Sander
  • Foam for float and ribbing (optional)
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Instructions

    • 1

      Coat your mold with several layers of mold release wax. Between five and 10 coats should be adequate to safely remove your boat from the mold.

    • 2

      Place a layer of fiberglass cloth over the mold. The cloth should completely cover the mold. Coat it with resin and allow it harden at least overnight.

    • 3

      Place a layer of Kevlar fabric on top of the hardened fiberglass. The Kevlar fabric should be large enough to completely cover the mold. Mix up a small amount of epoxy and hardener and begin to coat the Kevlar. Since the epoxy and hardener can become hot if allowed to sit for too long, continue to mix up small batches of epoxy mixture until the fabric is completely coated. Allow to dry at least overnight.

    • 4

      Examine the dried Kevlar for any bubbles or gaps. Use the sander or extra Kevlar material to correct these mistakes before repeating Step 3 with a second layer of Kevlar.

    • 5

      Remove the dried boat from the mold. Attach strips of wood, such as mahogany or ash, to the boat with steel screws on the outer and inner edges. Use glue and clamps to hold in place. Strips should be cut to the length of the boat and about 3/4 inch in height. A gel coat can be applied to the interior of the boat but is not necessary.

    • 6

      Add a float or air tank to the bow and stern of the boat using either foam or wood cut to fit into the boat. The foam or wood should be cut to fit into the bow and stern. It should allow for an open area beneath it. Epoxy can be used to attach the foam or wood.

    • 7

      Cut strips of foam to serve as the ribbing strips of a canoe. These will serve as a framework to help the boat maintain its structure. Strips should be cut about 2 inches wide. Each strip should be long enough to fit into the floor of the canoe and extend up the side walls of the canoe toward the gunwales. Glue the strips in place on the floor of the canoe. Cover the floor of the canoe with Kevlar fabric and epoxy.

    • 8

      Install finishing pieces, such as seats and seatbacks as well as oarlocks. Oarlock hardware can be purchased and installed using screws or included fasteners. Seats may also be purchased and installed following the manufacturer's specifications. Primitive seats can be made using wood, or made using nylon seat webbing.