Coaming Construction, Part 1

Coaming Construction, Part 1

Two thin layers of approximately 3/16" thick by 2" wide ash was bent inside the cockpit cutout. The thin ash
easily bent inside the cutout. No steam or heat was necessary. The Outer Island plans specify a smaller cockpit,
but I used the Guillemot size cockpit which is about 6" longer. I modified the stock Guillemot cockpit plans by
rounding over the front of the cockpit. I'll be able to use the same size spray skirt on both kayaks.

A posterboard template was made of the cockpit cutout
and it was used to mark the shape onto the deck. A fine
tooth Bosch blade was used in a jigsaw to make the cut.

These blades make a very smooth cut.

The cutout was faired with a curved sanding block.

The cockpit is tighter fitting than the Guillemot despite the
same size cockpit opening. The Outer Island has a
lower deck and consequently fits tighter in the thigh area.
I plan to add knee hooks to the coaming to mimic the fit
of the smaller, specified cockpit.

Ash forms the vertical portion of the coaming

The thin cut ash easily made the bend around the cutout.

Thirty minute epoxy was used to glue the first layer of ash
to the cutout. Strapping tape held the ash tight to the
cutout until the epoxy set.

Spring clamps used to attach inner layer of ash

Epoxy thinkened with fumed silica to a Vaseline like
consistency and color was used to make a fillet around
the outside of the coaming. The epoxy was placed in a
ziplock bag with a corner snipped off. A bead of epoxy
was squeezed out to form the fillet. The rounded end of a
popsicle stick was used to shape the fillet. A squeegie
was used to clean up the excess epoxy on the ash and
deck.

After the fillet was formed, the second layer of ash was
bent inside the first layer. The leftover thickened epoxy
was used to attach the inner layer.