Building the "Swiss Army Knife" of Small Boats...Wood Duck Double #19: Rounding the Edges of Hull and Deck

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Blog entry by DustyMark posted 07-04-2020 06:46 PM 1342 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 18: Filleting and Fiberglassing the Hull-to-Deck Seams Part 19 of Building the "Swiss Army Knife" of Small Boats...Wood Duck Double series Part 20: Just Had to Sit in the Kayak! »

Prep for Fiberglass
Rounding the edges is a preparation step before applying fiberglass. Some people leave their edges pretty sharp. I like to round mine over a fair bit for comfort and impact protection. This boat will see harsh use being dragged over beaver dams, ramming my way through flooded timber, enduring the dogs claws as he gets back in after a retrieve, and riding in my truck box down dirt roads. Sometimes the epoxy under the joint will appear as I round the edge over, but I don’t consider that a problem since there are epoxy fillets and fiberglass tape underneath and a coat of fiberglass over the top.

A sharp block plane removes the wood quickly, yet in a controlled manner.

Here’s the bow after planing.

A view of the stern.

With the edges rounded over, I switch to my Mirka random orbital sander with an 80-grit Abranet disc. I sand the whole kayak with this. Since I’m not varnishing, I stopped at 80 grit.

Videos of the Final Results
Here's a link to a video showing the deck ready for fiberglassing after the edges were rounded. Here's a link to a video showing the hull ready to go.

It’s definitely looking more like a kayak.

I’m looking forward to getting it on the water.

Fiberglass the hull.

-- Mark, Minnesota

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