DIY Foam Kayak Build

[Sheldon]

There ok. Heavy and clumsy through the water if your paddling it. With the trolling motor and battery it was even heavier. I think for a small lake, ponds and decent size creeks and rivers there fine. But I wouldn’t want to pull it over sand bars all day.
They are wide and stable.

If you have a TSC near by they will have the big foam blocks I used and they will give them to you.
I used expanding foam to connect it all together with the chemical reaction of the expanding foam and clamped them together. Worked great you will break the block before you break the joint.
I would use less conduit if I did it again. It protects the foam from rocks which helps but not sure it’s needed if you wrap it maybe one runner front to back on bottom and a transom for the motor


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Will have to check TSC out never thought to look there.


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[ImThere]

Will have to check TSC out never thought to look there.


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They are the blocks they ship the trailers on


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[Sheldon]

Got out for a bit this week. Really enjoying it.

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[Amarty734]

What would the main advantages of this type of kayak be over a normal commercially produced model? Just weight mostly? I can't imagine it would be better in easy of paddling, speed, stability, or durability.

 

[Sheldon]

What would the main advantages of this type of kayak be over a normal commercially produced model? Just weight mostly? I can't imagine it would be better in easy of paddling, speed, stability, or durability.

I like to make stuff mainly and I am cheap. I am not willing to spend several hundred $$ or more and realize this isn't my thing or I don't like this boat. If I take out the Turkey lounger seat I bought (which I did by the way it was taking up too much room, replaced with some ply and a stadium seat I picked up today at the thrift store for $2) I have less than $150 in it including buying a paddle (which I have learned is too short, guess we'll stretch it a bit).

Also something like this you can make exactly how you want it (plus your kids can help). Want fast, make it long and narrow. Want stable, wider and add more foam. Been testing this out and there are things I want to change. For example I have decided I don't care for the pontoons (get in the way of my anchor trolley) yet still want some additional stability. Simply going to remove pontoons, flip over kayak add foam runners along the edge at the center of the cockpit, glue and paint. If those don't do what I want will plane them off and do something else. I can drill as many holes as I want, move stuff around, heck I could cut the thing in half and add 4' to the length or take off 2' if I want. Honestly can't think of a commercial product you could do that with. From a commercial boat you got what you got, love it or hate it not much you can do.

For durability I can only go with the what the guy who designed them tells us. He has been using his for years, made changes, and even had something completely puncture the bottom. He cut out the punctured area, glued in some new foam, recovered and painted it, back on the water. He has pics standing in his boat held up by a couple sawhorses (I'm not going to do that). The foam on mine is covered with Kevlar fabric. I've been intentionally rough with it, dragging it across gravel parking lots and concrete driveway. Paint has worn off but no damage to the fabric. Time will tell of course but on the up side foam doesn't sink. Here is info on the process of "glassing" something like this with Poor Man's Fiberglass. I have been greatly pleased by the results.
PMF Torture Test and Comments

In the end it is what it is. Some folks are into this kinda stuff, some not. I enjoy showing folks my $150 pile of foam, others like showing off their $3500 Hobie Angler Pro. In the end they both accomplish the same task, getting you out and enjoying some time on the water. Sorry long answer.....................

 

[ImThere]

What would the main advantages of this type of kayak be over a normal commercially produced model? Just weight mostly? I can't imagine it would be better in easy of paddling, speed, stability, or durability.

FYI ON DIY
I did it myself and no other reason. A lot of times diy isn’t cheaper than buying commercially


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[Sheldon]

FYI ON DIY
I did it myself and no other reason. A lot of times diy isn’t cheaper than buying commercially


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Plus what awesome story ever starts with “remember when we bought that boat” vice “remember when we glued all that foam together and tried to....”


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[EricS]

What would the main advantages of this type of kayak be over a normal commercially produced model? Just weight mostly? I can't imagine it would be better in easy of paddling, speed, stability, or durability.

Just for the thrill of doing it. It can be as fast, stable, or durable as you want to make it. It’s all in what you want to make and the time you put into it.

 

[Sheldon]

Update. Finished, for now. Added HDPE skegs (?) to help with tracking. Probably add a couple more but it helps considerably as it floats kinda like a pile of foam would be expected to float. Took the boy out with me last week so we were pushing #300. Had no problems and had the 9 year old paddle us back against a stiff wind. Found my motor .

Can stand up in it but I don’t feel comfortable. Added some pontoons and it is pretty solid standing with them but slows you down. Trade offs. So far very happy with it for a fishing yak. Best news is that I have caught fish every time out.

Next, see if you can shoot from it. May move the rear bulk head to make some room to lay back and see how it does in the marsh.

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[Benman]

That’s a really cool build Sheldon...great job!

 

[DaveT1963]

Looks pretty cool. The only thing I will say guys is consider the weather.... take that from someone who took a plunge a few times in freezing weather. Also, ALWAYS have a life preserver handy or on you - amazing how hard it is to get waders or even knee high rubber boots off once filled with water.

For me it was worth it to spend the bucks and get a nucanoe frontier 12 - one of the best hunting tools I have ever used.

 

[fbwguy]

Very Impressive Sheldon. I think it turned out really awesome.

 

[stumpywarden7]

Really slick idea and build.


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[IkemanTX]

I’m getting more and more tempted to make one myself.... my problem is I won’t have time to finish it before season with how my work schedule is looking. I might start out buying one, and build one from there after I decide how I want everything set up.


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[Sheldon]

I’m getting more and more tempted to make one myself.... my problem is I won’t have time to finish it before season with how my work schedule is looking. I might start out buying one, and build one from there after I decide how I want everything set up.


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Most of the time was spent waiting for glue to dry. Using the power planner is a huge timesaver. Was able to do most of the shaping in less then 2 hours. Going to start building one for the boy this weekend. Now that I have a basic understanding of how it goes together will see how long it takes.

Will say if you decide to build one go with the cotton fabric to skin it per the instructable. I used the Kevlar because I have roll of it. The problem with it is, as he mentioned in the build, synthetic fabric doesn’t hold the paint well. Probably change that out this winter. Now if I could convince myself to shell out the $ to do the right way with the epoxy would be a different deal. May do that at some point but since I am still figuring out what I want it’s nice to be able to pull the stuff off and change things.


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[Sheldon]

Looks pretty cool. The only thing I will say guys is consider the weather.... take that from someone who took a plunge a few times in freezing weather. Also, ALWAYS have a life preserver handy or on you - amazing how hard it is to get waders or even knee high rubber boots off once filled with water.

For me it was worth it to spend the bucks and get a nucanoe frontier 12 - one of the best hunting tools I have ever used.

Been checking out some videos on that boat looks nice!


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[IkemanTX]

If I ever end up doing a foam one, I plan on essentially making a 10’ nucanoe clone with integrated lights, power management, and steering.
I think their hull design and stability are unbeatable, and would straight up rip off the design. I’m not benefiting from it financially, so patent laws don’t apply
I’m thinking brake line tubing would be perfect to run wiring and steering cabling. Is I could ever afford a torqeedo 403 light, I’d LOVE to have one on there too. But, I’m not made of money!


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[Sheldon]

Right around 2 hours to cut everything out and glue first layer.


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[Sheldon]

If I ever end up doing a foam one, I plan on essentially making a 10’ nucanoe clone with integrated lights, power management, and steering.
I think their hull design and stability are unbeatable, and would straight up rip off the design. I’m not benefiting from it financially, so patent laws don’t apply
I’m thinking brake line tubing would be perfect to run wiring and steering cabling. Is I could ever afford a torqeedo 403 light, I’d LOVE to have one on there too. But, I’m not made of money!


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Was looking at the nucanoe again last nite. Man that thing looks stupid stable! Would need to add another 9” to this one at the center for those results. May see if it can find a new home for this one end of summer and follow your lead and clone one.


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[IkemanTX]

Was looking at the nucanoe again last nite. Man that thing looks stupid stable! Would need to add another 9” to this one at the center for those results. May see if it can find a new home for this one end of summer and follow your lead and clone one.


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I’m looking at going so far as to borrow @Scoutman ‘s frontier 12 and flip it over and copy the underside to scale. I think a lot of their stability comes in their tracking channels and kiss-ofs. The kiss-ofs cause suction when one side wants to lift. So, one side suctions down, while the other increases flotation as it dips. I don’t know how I’d manage the kiss-ofs with foam and poor man’s fiberglass, though.

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