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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

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