SAVEwith a - Canoe & Kayak
SAVEwith a - Canoe & Kayak
SAVEwith a - Canoe & Kayak
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KAYAK DESIGN & BUILDING<br />
The birth of a kayak<br />
- Dusky Bay Classic<br />
THE IDEA<br />
In 1992 the concept of manufacturing a<br />
polyethylene kayak in two sections, then joined<br />
in the centre to form a long sea going double, was<br />
born.<br />
More than 10 years on Max had a new longer oven,<br />
and finally the chance to get on with his double<br />
sea kayak project.<br />
THE DESIGN AND CRAFTING HER<br />
Using the foundation of our composite 6.25mtr<br />
Dusky Bay II, Max started on a shorter<br />
polyethylene model which would cater for<br />
weekend paddling in open waters, yet handle<br />
changing weather and tidal conditions.<br />
HULL: Much of the hull work was done, but in<br />
plastic, large flat areas are a no-go area, so the<br />
beautiful lifting rails, used in the elite ‘Torres’ sea<br />
kayak, shaped the hull beautifully, giving it extra<br />
strength, speed, and stability. Running the rails<br />
all the way to the bow, enabled any wash to shed<br />
early, making for a dryer deck.<br />
DECK: Here is where the fun began! We wanted<br />
good stowage in front and rear, without<br />
compromising a good length between cockpits to<br />
prevent paddle clashing. Could we fit a centre<br />
hatch in? How to make the cockpits comfortable<br />
for thigh and foot? There are similarities to our<br />
other sea kayaks, but working out where it all sits<br />
best, and then getting everything to the right<br />
measure and level, certainly took time.<br />
GETTING HER MOULDED<br />
After months of moulding bog, fibreglass, foam<br />
and sanding, the beast was ready for the Foundry.<br />
With eight of the team to lift her onto the trailer,<br />
by Sandy Wilson<br />
she was off and away. At the Foundry, Brett was<br />
not looking forward to the project. She was one<br />
big girl. Within a few weeks we had the alloy hull<br />
home. Many hours of sanding and sore hands<br />
went into getting a smooth finish. Just when we’d<br />
had enough, the deck turned up. The area was<br />
not as big, but detail was more complex, so more<br />
sanding, and more sanding .........<br />
A heavy duty spider frame was made to lift her in<br />
and out of the oven. Max progressed with the<br />
seats, beefy rudder and all the finishing touches,<br />
while the team sanded and sanded .............<br />
THE FIRST BIRTH<br />
Finally, a long time down the track, the<br />
‘DUSKY BAY CLASSIC’ was ready to be loaded up<br />
and produce.<br />
You wait with baited breath at the first birth of a<br />
new model. Did you get the shrinkage percentage<br />
right, will the hatch rims come away, or will they<br />
buckle with pressure? Is the plastic distributed<br />
correctly, and is the thickness right in vital places?<br />
It is fantastic to see a new project come to<br />
completion. The process is long, and patience is<br />
not every one’s virtue, but the first birth ............<br />
THE BEAST HERSELF<br />
So, once the fittings were complete - this was no<br />
easy task either - the ‘Dusky Bay Classic’ was ready<br />
to be paddled. Her hull design is smooth and fast<br />
on the water. The seats/backrests are<br />
comfortable, with ample thigh and foot room. The<br />
sturdy rudder is easy to lift and drop, and the<br />
footrests manoeuvre the boat effortlessly.<br />
So, we’re more than pleased with her! We hope<br />
you enjoy her too!<br />
And it’s onwards and upwards to the next project<br />
around here (but it won’t be quite so BIG!)<br />
Dusky Bay Classic<br />
Length<br />
544 cm<br />
Width<br />
74 cm<br />
Depth<br />
39 cm<br />
Weight<br />
44 kg<br />
Volume<br />
685 Litres<br />
Cockpit<br />
71 x 44 cm<br />
Accessories Paddles, lifejackets,<br />
spray decks<br />
Retail Price $2950<br />
Max<br />
ISSUE THIRTYthree • 2005 41