How to Build a Plywood Kayak

Kayaks can be purchased at many locations, but it is possible to build your own out of plywood. The simplest way to build a plywood kayak is through the use of a kit that is accompanied by instructions and detailed plans. These kits are available through select suppliers that specialize in water recreation and can also be found online. Most kits include the needed smaller items to make your plywood kayak. All you need to supply is the larger items such as the plywood and any decorative touches.

Things You'll Need

  • Kayak kit
  • Handsaw
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Instructions

    • 1

      Obtain a kayak kit and remove all the included parts. Make sure there are at least two stem pieces in the kit. It should also include the correct number of rib pieces that will determine the length of your kayak.

    • 2

      Use a handsaw to cut the side and bottom panels for the kayak. Follow the patterns provided in the kit. Two sheets of plywood should allow for the construction of a 15-foot kayak. Use a splice to connect the two sets of side panels together. Wrap the connection in fiberglass tape and allow at least 24 hours to dry.

    • 3

      Cut a 45-degree angle from top to bottom at each end of plywood to ensure each end of the vessel is even. Place a stem on both ends of one sideboard using wood glue and allow one hour to dry. Use a drill to apply wood screws every 4 inches for a tighter and more secure hold. Connect one end of the sideboards to the stems with wood glue and wood screws. Allow another hour for the glue to dry. Attach one end of the remaining sideboard to one of the stems with wood glue and 1-inch wood screws.

    • 4

      Fasten the ribs to the kayak following the kit instructions. Use wood screws in addition to the wood glue such as in Step 3 to securely fasten the connections together. Allow an hour for the glue to dry and clamp the ribs in place with C-clamps. Attach ribs to the sideboards using wood screws.

    • 5

      Insert the rub rails into position to protect the kayak sides from any damage. Use 16-foot lengths of plywood and cut strips 1.25 inches in width. Use penny nails to attach the rub rails to the upper sides of the kayak. Place the nails every 4 inches for a secure hold.

    • 6

      Fasten the bottom of the kayak to the rest of the vessel. Turn the side rails so they are upside down and sitting on sawhorses. Lay the bottom section on the bottom of the side rails. Trace the outline included in the kit on the bottom board and cut along the outline. Attach the bottom once cut with 1-inch wood screws. Shave off any excess wood with a wood shaver until the bottom is even with the sideboards.

    • 7

      Coat the kayak in fiberglass mold. Mix a batch of silica with vinyl resin to create a paste. The best way to mix this is in a 5 gallon bucket. Use a paint mixing stick to stir the concoction and then spread the paste on the kayak. Place an extra coating wherever wood connects. Allow 12 hours for the paste to cure on the kayak.

    • 8

      Place a coat of paint or varnish on the kayak. Ensure the paint you choose is exterior and waterproof. Fiberglass may deteriorate if left unprotected in sunlight or in water overtime.