How to Make a Plastic Formed Kayak

Kayak manufacturers use plastic to make kayaks using several different methods. The most common methods include rotomolding and thermoforming. During the latter, a manufacturer uses a sheet of plastic and an exact male-mold replica minus the plastic thickness of the finished kayak to form the kayak. Both require large industrial ovens. Thermoforming makes a kayak with similar appearance and performance to a fiberglass kayak. It costs $500 to $1000 less per boat versus fiberglass.

Things You'll Need

  • Thermoform plastic sheet
  • Frame
  • Clamps
  • Industrial oven
  • Kayak vacuum mold
  • Vacuum pump
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Instructions

    • 1

      Clamp a sheet of thermoformed plastic into a metal frame designed to fit it. The size of the sheet depends on the length, width and depth of the finished kayak.

    • 2

      Heat a large industrial oven to 400 degrees Fahrenheit.

    • 3

      Slide the frame and plastic into the oven. When the plastic reaches 400 degrees, pull it and the frame out of the oven. At this temperature, it becomes rubbery and flexible.

    • 4

      Place the frame over the vacuum mold and lower it until the plastic seals against the mold's edge.

    • 5

      Turn on the mold's vacuum pump. The vacuum pulls the rubbery plastic down against the mold. It takes the shape of the final kayak.

    • 6

      Allow the plastic to cool to room temperature.

    • 7

      Trim the boat out with a seat, foot braces and deck lines according to the plan.