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Building the "Swiss Army Knife" of Small Boats...Wood Duck Double #45: Spray Decks

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Blog entry by DustyMark posted 08-10-2020 09:16 PM 297 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 44: Dog Cockpit Attachment Part 45 of Building the "Swiss Army Knife" of Small Boats...Wood Duck Double series Part 46: Performance Assessment »

Dog Cockpit
I had only two days to complete the dog cockpit attachment and sew the spray decks before we departed on our annual paddling-centered camping trip to Lake Superior. I got it all done with a couple of near-sleepless nights!

Here’s the attachment all rounded and sanded. I sealed it with a coat of epoxy.

Hip Braces
There are three different paddling positions, so I built three sets of hip braces.

This photo shows the permanent hip braces at the stern position and the white oak cleats to hold the mid and forward hip braces to the floor and the mid hip brace cleats glued to the gunnel. The forward hip brace mounts at the top to a cleat on the underside of the spray deck.

I used contact cement to bond 3/4” minicell foam to the braces. It takes 3 or 4 coats to get adequate coverage on the foam since it keeps soaking in.

Spray Decks
The process of sewing the spray decks is pretty straight-forward canvas work.

Begin with the deck and allow at least 1/2” for seam allowance. I used Shelter Rite vinyl for the decks and 6 ounce polyester for the bungee sleeve. Here I’m fastening the bungee sleeve to the deck with basting tape before sewing it.

I used spur grommets to run the bungee cord in and out of the bungee sleeve. I reinforced the sleeve with vinyl before attaching the grommets.

Sewing the bungee sleeve with a half-felled seam.

At this stage, I’ve got a nice cockpit cover.

These next steps transform it into a spray deck. First I make some relief cuts.

Then I trimmed the vinyl to within 1/4” of the coaming rings with scissors.

Mark the coaming screw holes with an awl.

A punch makes a clean hole.

The slightly undersized punch allowed the screws to grab the vinyl and “tent” it for applying vinyl cement to both surfaces.

Applying vinyl cement under the vinyl and to the deck.

You can see how the screws suspend the vinyl and give me room to work.

Applying vinyl cement to the coaming ring.

Tandem spray deck done. The clamps were in place until the glue cured and then I was able to drive the coaming screws for that section.

Solo spray deck done.

Dog cockpit done!

This was at the Meyer’s Beach sea caves in the Apostle Islands National Lakeshore.

Jam Cleat

This is the jam cleat for adjusting the seat in the middle or forward positions. I screwed it to a piece of white oak and then epoxied the white oak assembly to the underside of the deck using a Gorilla repair tape as a clamp. It worked well.

Next
Lake Superior performance assessment.

-- Mark, Minnesota



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