Building the Kayak

This West Greenland kayak was originally built by an Inuit hunter for a Canadian botanist in 1931.  It now resides in the Canadian Museum of Civilization in Ottowa.  Originally a commission for an avid female paddler,  we chose this design based on information she gave me and for it's classic 'Greenland' lines.   Building a replica is always an adventure for me.  With my own designs I can predict performance and fit and the construction process is greatly simplified.  With replicas the process is much different,  one can only choose a specimen that looks good and hope it performs well for you.   The method of construction is a process of taking measurements off a survey drawing and transferring them to the real kayak being shaped beside you.  To the effect that you are able to reproduce the original, you are successful.   A completed replica is a valuable contribution to the field of kayak reasearch.  

Note:  the following sequence may serve as a helpful adjunct to,  but cannot replace an instruction book or instructor.  Critical details in process and construction are ommitted.  Every kayak is different,  in this case nails replace lashings for some joints,  my own design, Ginnyak features different joinery.   Feel free to call me with any questions on details.
We mark the mortise and deck beam locations.



 We cut those mortises with a router.  Noisy and dusty but much easier than the alternative.



 After cutting angles on the ends of the gunnels,  we set up the frame and lock in the shape of the deck. 



I kerf the ends with a jig saw, fast, easy, and a perfect mating surface with no binding handsaws.  One of my secrets.



We make deck beams to replace the braces.



Marking for the curved deck beams.




The end kerfs are completed, the ends are pegged and lashed.



The deck beams are lashed.



The finished deck is still missing the Masik, or knee brace, which sits atop the gunnels.  End of day 1.



The keel is set to depth and held by cam straps.



We flatten the surfaces where the stems will mate to the gunwales.



Stem angles are chosen and cut, and the gunwale end profile is traced into the stems.



The stems are attached.



The end of the 2nd day.



The ends of the kayak are notched and a breasthook is fitted.



Deck stringers are fitted.



Steam bending in the ribs,  in the Ginnyak this is accomplished with precut lengths, with replica kayaks they are bent in under the keel,  trueing is accomplished by trimming and shimming.



Stringers are laid on and in this case, nailed to the ribs!

Building the coaming,  this takes more time than any other single process.  (forgot to take picture)



The completed frame is lightly oiled and needs to dry.  Do not oil the coaming.  End of day 3.



Stretching the wet nylon into place.



Sewing it up.



Dying the fabric.  End of day 4.



Coating the kayak.  Days 5 and 6.



Installing deck rigging, rub strips, and end knobs.  Day 7.



Carving a paddle. Days 5 & 6.



 
  A beautiful new kayak.

This kayak is for sale,  the cost is $2000 and includes the paddle.