How are Kayaks Made?

Kayaks are now deemed a famous means of making the most of water sports. They resemble canoes that are long, narrow, lightweight paddleboats and are pointed at both the ends. They also have a hull which refers to the hollow bottom shell of the boat. Kayaks are the water displacement water transport means, they tend to flow just below the surface that forces the water to be pushed aside as they move. As kayak sits low in the water, a deck is mandatory. It is semi-enclosed that covers the kayak’s top. The gist is to keep the waves from washing over the edges and filling the hull with water. The cockpit is placed in the deck center where the rider sits. The cockpit is surrounded by a coaming. Kayak also has interior braces and bulkhead, a cord named grab loop attached at each end for mooring and towing purposes, and interior floating devices.

Manufacturing process

  1. Loading the mold

Measured amount of granulated or powdered polyethylene plastic is combined with coloring agents and a precise amount is then added into a bottom of a two piece, thin walled aluminum mold for the deck or the hull. Then the mold is closed and the two halves are tightly secured.

  1. Molding the hull or deck

The mold is supported by a mechanical arm that can rotate the mold at the same time in two directions. It can also be moved or indexed from one process station or another. After the load, it is then moved to the heating station. As the heat melts the plastic, the mold is gradually rotated in two directions. The gravitational force flows the metal plastic to the front, rear and up the sides of the rotating mold, eventually covering the surface completely with a uniformly thick plastic skin.

Then the mold is indexed to the cooling chamber. When the mold is continuously rotated, it is gradually cooled with carefully directed sprays of air and then water. The kayak hull or deck hardens and then shrinks away from the mold. When the final cooling is done, the deck or hull is then removed from the mold.

  1. Assembling the shell

The hull and deck are then fit together at a single seam. Careful sealing guarantees that the shell acts as a single structural unit. When the sealing is done, a decorative strip is added to conceal the seam lining.

  1. Final assembly

The closed cell foam floatation aids are installed at each end of the kayak and stuck with adhesive. Many use the inflatable floatation bags. They help in keeping the kayak floating on the surface. If the design uses a bulkhead, then these pieces are bonded in place and sealed with a polyurethane sealant. Seat is suspended from straps supported by foam. Then a drain plug is equipped in a molded hole in the shell.

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