Making the Hull Panel Templates

The offsets for the Cormorant 16 can be found on the Squeedunk Kayaks webpage.  I multipled the spacing by 6% to stretch the length of the Cormorant to approximately 17' 2.5".  Rather than hand cut 2 sets of panels, I chose to make a template of the panels so that a router can be used to make copies.  I made the template 1/4" undersize so that a router guide bushing and spiral router bit can be used to cut the panels to the correct size.

A string line was strung along the bottom of the panels and the points were plotted on the panels.

Nails were driven at each point and a batten was clamped to the nails.  The shape of the panels were marked.

The template was screwed to the butt jointed panel.  I placed pink building foam under the hull panels so that the router bit would not cut into the work surface.

A jigsaw was used to cut outside of the marked line.  A block plane trimmed the panel to the line.  A fairing board was used to further dress the edge of the panel.

A router fitted with a guide bushing and a spiral bit was used to cut out the hull panels.

These are the hull bottom panels after being cut.

The hull has been assembled and a seal coat of epoxy has been applied.