Building the "Swiss Army Knife" of Small Boats...Wood Duck Double (WDD) #13: Fitting and Gluing the Hatches

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Blog entry by DustyMark posted 07-01-2020 02:32 AM 482 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 12: Tacking the Hull and Deck Part 13 of Building the "Swiss Army Knife" of Small Boats...Wood Duck Double (WDD) series Part 14: Installing the Hatch Rims »

Moved Kayak Build to the Basement!
After an enjoyable three-night camping trip, I’m back to working on the kayak. It’s hot and humid here now and the forecast calls for temps in the 90’s by the end of the week. I haven’t installed my floors in the basement finishing project, so I moved my kayak build to the new guest bedroom. Nothing like building in air conditioned comfort. It’s a straight shot up the steps, so the kayak fits…nice! I’ll paint it with stinky, oil-based duck boat paint in the garage.

Clever Design
The design of the hatches is quite clever and the end result is waterproof and secure. I built the Wood Duck 10 about five years ago and the hatches are great.

This is the stern hatch. The top layer is a spacer that gets glued under the deck. The next layer is the deck sill that is glued under the spacer. The actual hatch cover is carefully cut from the deck. The cut is started by drilling a series of 1/16” inch holes that provide a place for the jig saw blade to enter. That’s a cut you want to be careful with since the hatch cover is made from the already assembled deck. A mistake here would be very painful/expensive. However, the kit provides alignment holes in the deck and in the spacers.

The bow hatch area is smaller and requires the spacer and the sill to be beveled with a hand plane.

This is the stern hatch. The hatch spacer and hatch sill are glued in place with epoxy thickened with silica powder. You can never have too many clamps during a boat build!

I had enough clamps to glue the bow hatch at the same time.

I need to wait until morning for this assembly to cure strong enough to continue by gluing in the hatch rims. I’ll also glue the hatch stiffeners to the bottom side of the hatches. None of that will take too long, so tomorrow will be a good day to hang doors and fit HVAC drops in my basement refinishing project!

-- Mark, Minnesota

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