Stitch and glue

A method of building kayaks out of plywood.

The basic process for Stitch & Glue is: Note there are many possible variations from this method.

1. Scarf together several pieces of plywood (Make one big sheet out of several 4x8 sheets. Double glassed butt joints are easier and good as well.Use 4 oz fiberglass.
2. Draw the parts full-sized on the plywood. (correct shape is desirable but it is more important that the 2 halves are identical and that there are no concave curves)
3. Cutout the parts.
4. Drill small holes along the edges of the parts every 3" to 5".
5. With short lengths of wire, stitch the panels for the hull together through the drilled holes. Make sure that the edges meet nicely and that there is no twist in the hull.
6. Glue the interior seams with a fillet of thickened resin covered with fiberglass tape.
7. Repeat 5 & 6 for the deck.
8. Bond together the deck and hull in a similar manner.
9. Cut the wires and sand them down. Do not pull them out as this creates hollows under the glue where rot can set in.
10. Radius the corners.
11. Fiberglass the outside. (optional but recommend on the bottom of the hull)
12. Sand and Paint.
13. Paddle.