Welcome to professionally designed Boat Plans by Nick Schade

How to Build a Stitch and Glue Kayak - Free Building Videos and Instruction

How to Build a Stitch and Glue Kayak - Free Building Videos and Instruction

October 18, 2024

Nick Schade and his friend Bill put together a Petrel Play SG Kit from Chesapeake Light Craft and kept a camera running the whole time. Below is the Complete Series. You can click on the Episode Title to watch each video, or click on the time stamp to get the information you need.

VIDEO CHAPTER INDEX

E1- BUILD YOUR OWN ADVENTURE: THE PETREL PLAY SG KAYAK

0:18 Launching the Petrel Play SG
4:27 Design Discussion - What features
8:00 Design History - What lead up to this design
12:48 Petrel - How it compare to earlier designs
15:19 Petrel SG - How it compares to the Strip Built version
20:48 Wood Kayak Durability - Is it good enough to make a kayak?
23:47 Why the Petrel Play?

E2 - UNBOXING THE KAYAK KIT - STITCH AND GLUE PETREL PLAY

0:51 Introduction to the unboxing of the kit
2:45 What is in The Epoxy Box
6:23 Opening the Big Box
8:15 Fiberglass Tape
8:57 The Builder's Manual
9:45 Looking at the Stitching Wire
10:22 Discovering the Hatch Rims
11:05 Discussing the roll of Fiberglass Cloth
12:25 Identifying Parts and Pieces
14:06 Finding the Bottom Panels
16:40 Sorting out the Deck Sides
18:53 Differentiating the Hull and Deck Forms
20:08 Finding the Cockpit Parts
22:21 Distinguishing the Hatch Parts
25:38 The Benefits of Pre-Beveled Plywood Panels

E3 - STAINING THE PANELS - STITCH AND GLUE PETREL PLAY

0:23 Episode Introduction
2:13 Example of a Stained Kayak
2:59 Finding the Parts to be Stained
5:18 Selecting the Stain
9:27 Applying the Stain
12:10 Eliminating Blotchiness in the Stained Panels
15:15 Introduction to Mixing Epoxy
25:25 Introduction to Applying Epoxy

EPISODE 4.1 — 4.4 - PUTTING TOGETHER THE HULL OF THE S&G KAYAK

E4.1 - ASSEMBLING THE HULL PANELS ON A STITCH AND GLUE KAYAK - PETREL PLAY SG BUILD

0:20 Introduction
0:40 Identifying the Hull Parts
4:14 Fitting the First Bottom Puzzle Joints
5:39 Introduction to Using CyanoAcrylate (CA) Glue
7:26 Using CA Glue to Spot Welding Puzzle Joints
17:55 Assembling the Side Panels
23:05 Discussion on Assembling the Hull

E4.2 - SETTING UP THE HULL ON A STITCH AND GLUE KAYAK - PETREL PLAY SG BUILD

0:21 Introduction to Setting Up the Panels into a 3D Hull Shape
2:21 Start Assembling The Panels
2:42 Cutting the Copper Stitch Wires to Length
4:43 Safely Picking up and Moving the Freshly Assembled Panels
5:42 Installing Stitching Along Bottom Keel Line
11:40 Installing The First Forms
15:37 Opening Bottom Two Panels Like a Book
20:43 Stitching on the Side Panels
21:59 Drop the Side Panels Into the Forms
24:36 Installing the Remaining Forms
27:49 Installing Narrow Stealer Plank at the Bow of the Hull

E4.3 - STITCHING THE HULL ON A STITCH AND GLUE KAYAK - PETREL PLAY SG BUILD

0:20 Introduction To Stitching Together the Plywood Hull Panels
3:00 Start to the Stitching with Copper Wires
4:28 Removing the CNC Tabs
7:41 How to Tighten the Copper Wire Stitches So They Are Tight But Don't Break
16:20 What is Good vs Poor Wiring
19:48 Closing up Bow Seam
29:50 Outro to Stitching

E4.4 - MAKING KAYAKS WITH SUPERGLUE - PETREL PLAY SG BUILD

0:16 Introduction to Spot Welding using CA Glue
3:03 Aligning the Seams Before Gluing
4:13 Spot Welding Seams with CyanoAcrylate (CA) Glue
10:25 Aligning the Seams at the Ends
14:26 Recap of Assembling the Hull

E5 - EPOXY FILLET FUNDAMENTALS ON A STITCH AND GLUE KAYAK - PETREL PLAY SG BUILD

0:11 Introduction to Filleting
1:25 Bill's Reaction to Paddling the Petrel Play
10:33 Pulling out the Copper Wire Stitches
16:30 What are Fillets and Why Do We Use Them
20:29 Epoxy Mixing Cups
25:20 How to Make the Epoxy/Wood Flour Filleting Mix
29:39 How to Dispense the Filleting Mix
35:15 Shaping the Fillets
47:26 Smoothing Messy Fillets with Alcohol
49:00 Filleting the Stems
56:00 Outro

E6 - THE ART OF KAYAK INTERIOR FIBERGLASS: A DETAILED HOW-TO GUIDE - PETREL PLAY SG BUILD

0:14 Introduction to Fiberglassing
1:44 When is the Best Time to Fiberglass
3:38 Layout and Cut the Fiberglass Cloth
8:42 Getting Prepared to do the Fiberglassing
9:40 Introduction to Applying Epoxy
10:48 What is Bridging and How Do We Deal With It?
17:38 When to Add More Epoxy
22:19 Working in the Tight Ends of the Hull
26:40 How to Do "Grunge Cupping" Removing Excess Epoxy
45:23 Wrap Up

E7 - FILL COAT, PUZZLE JOINTS, & FIXING MISTAKES - BUILDING PETREL PLAY SG

00:31 Introduction To Fill Coats
2:38 Trimming the Hardened Fiberglass Edge
4:12 Dealing with Edge Bubbles
6:13 Applying an Interior Fill Coat
10:24 Assembling the Deck Parts
11:34 Fitting the Puzzle Joints
12:41 Spot Welding Puzzle Joints
14:45 Finding a Mistake And Dealing With It.
16:05 Disassembling a Mis-glued Puzzle Joint
17:38 Discussion About Dealing With Mistakes
19:35 Cleaning up the Fixed Joint
21:37 Test Fit
27:49 Outro

E8 - HEAT, BEND, ASSEMBLE: A DEEP DIVE INTO S&G KAYAK HATCH CONSTRUCTION - PETREL PLAY SG

0:13 Introduction To Assembling the Deck
3:00 Identifying the Deck Parts
4:06 Stitching Together the Deck Bow
6:12 Stitching Front Deck to the Form
8:04 Removing Epoxy Messes
9:20 Attaching The Rear Deck to Form
11:04 Installing The Deck Sides on Forms
11:57 Stitching The Sides into Forms
11:55 Setting up The End Panels
16:59 Stitching up The Cockpit Recess
25:06 Starting to Assemble the Hatch Recesses
27:26 Gluing Together the Hatch Recess Parts
28:22 Reinforcing The Hatch Recess
29:50 Using Heat to Shape Plywood Hatch Parts
30:47 Closing The Hatch Recess
39:22 Fitting The Hatch Ring
55:14 Wrap Up to Assembling the Hatches

E9 - CRAFTING THE PERFECT KAYAK DECK: STITCHING AND GLUING MASTERY - PETREL PLAY BUILD

0:19 Introduction To Creating the Kayak Deck
2:41 Why the Recessed Hatches?
4:00 Where Do the Hatches Go?
5:54 Beveling the Recessed Hatches
7:30 Fitting the Cockpit Pieces
14:40 Fitting the Back Hatch Recess
15:24 Adjusting Bevel Angle
18:39 Fitting the Front Hatch Recess
18:59 Adjusting the Front Hatch Bevel
26:40 Recap on Assembling the Deck
29:00 Surfing through Sea Gulls

E10 - WIRING AND SPOTWELDING THE DECK - PETREL PLAY SG

0:00 - Introduction and Project Overview
0:35 - Current State of Deck Assembly
1:02 - Process Overview for Deck Assembly
1:43 - Addressing Cockpit Combing Alignment
4:59 - Working on the Deck Seams
13:02 - Maintaining Panel Fairness and Form Alignment
18:03 - Focus on Front Deck and Hatch Assembly
31:47 - Conclusion and Next Steps
32:15 - Behind the Scenes Insights
34:13 - Outro and Channel Information

E11 - CREATING FLAWLESS FILLETS - PETREL PLAY SG

0:17 Introduction to Filleting the Deck
4:06 Pulling the Stitch Wires
5:05 Dealing with Twist in the Panels
5:46 Intro to Filleting with Epoxy and Wood Flour
6:10 Sanding the Interior
7:03 Discussion on Filleting Tools
14:54 Making Filleting Mix from Epoxy and Wood Flour
16:04 Judging Proper Filleting Mix Thickness
17:54 Piping Mix onto the Seams with a Cake Bag
20:03 Shaping the Fillets
33:57 Mistakes in Mixing Epoxy
35:59 Fillets around the Hatches
39:11 Touching up Missed Spots
38:19 Judging Proper Fillet Size
39:43 Cleaning up the Fillets
45:56 Front Hatch Finger Divots

E12 - MASTERING FIBERGLASS APPLICATION: KAYAK INTERIOR BUILD TECHNIQUES - PETREL PLAY SG

0:00 Preview
1:15 Overview of the Kayak Kit and Design
1:48 Previous Episode Recap and Current Project Stage
2:23 Sanding Process and Surface Prep
4:00 Epoxy and Fiberglass Safety Measures & Respirators
7:17 Sanding Demonstration and Further Safety Tips
10:07 Glassing the Interior - Introduction and Planning
11:51 Examining Glass Options and Application Techniques
14:47 Preparation for Glassing the Stern
15:58 Discussion on Bridging and Epoxy Mixing
17:57 Applying Epoxy With a Roller and Squeegee
26:02 Addressing Dry Spots and Bridging
28:55 Introduction to Epoxy Application
30:23 Identifying Areas Needing Attention
31:46 Using a Squeegee
34:07 Dealing With Bridging
38:41 Grunge Cup to Remove Excess Epoxy
42:24 Comparing the Roller to the Dump & Spread Method
45:01 Demonstrating the Grunge Cup Technique
47:06 Reviewing the Final Result
49:12 Rationale Behind Using Fiberglass and Epoxy

E13 - STITCH & GLUE KAYAK HULL PREPARATION: SHAPING SEAMS & STEMS FOR FIBERGLASSING - PETREL PLAY SG

0:14 Introduction to this Episode
2:09 Demonstrating Fiberglass Trimming Technique
3:40 Handling Non-Wetted Fiberglass and Holes
4:24 Organizing Workspace After Trimming
5:05 Emphasizing Low-Cost Equipment for Kayak Building
5:21 Inspecting the Hull Assembly
6:01 Removing Forms from the Hull
7:05 Addressing Sharp Edges and Drips on the Hull
10:58 Prepping for Fiberglassing the Hull's Exterior
20:32 Discussing Craftsmanship Details and Adjustments
37:19 Clean Up the Chines
50:48 Stain Correction & Preparation for Fiberglassing
1:00:31 Conclusion

E14 - MASTERING KAYAK FIBERGLASSING: TIPS AND TRICKS - PETREL PLAY SG

00:23 Introduction
00:29 Overview of the Fiberglassing Process
00:35 Preparing the Hull for Glass
01:05 Filling the Stem Gap
01:58 Begin Fiberglassing
03:03 Strategy for Glassing the Outside Compared to the Inside
07:03 Working on the Stem
15:01 Additional Finishing Steps
30:25 Fill Coat Application After a Partial Cure

E15 - HANDCRAFTING A KAYAK: GLASSING COMPONENTS FOR PROTECTION AND STRENGTH - PETREL PLAY SG

1:04 Bulkheads and Cheek Plates Explanation
1:21 Combing Ring and Skeg Kit Overview
2:23 Preparing Small Parts for Fiberglass Application
3:27 Applying Epoxy and Fiberglass
6:02 Ensuring Complete Saturation with Epoxy
7:13 Additional Epoxy Application Tips
8:49 Working on Small Assembly Projects
10:50 Trimming and Preparing the Hull
12:12 Coaming Riser Assembly Process
16:13 Applying Epoxy for Coaming Riser Assembly
18:21 Clamping and Aligning Coaming Riser Layers
19:13 Epoxy Application for Final Layers
22:29 Preparing for Fiberglassing Other Components
31:09 Applying Glass to Other Components & Using Peel Ply
36:16 Closing Remarks and Future Plans

E16 - SKEG PARTS AND END POUR - PETREL PLAY SG

0:00 Introduction
1:38 Skeg Box Construction
2:19 Purpose of a Skeg on a Kayak
6:57 Control Slot Construction
11:30 Shaping the Kayak Skeg Fin
19:38 Reinforcing the Skeg Pivot Hole
21:17 Preparing Skeg Spacers
24:48 Skeg Trailing Edge Reinforcement
26:39 End Pour Using a Dam Technique
30:44 Mixing and Applying Epoxy
33:42 Discussion on Usefulness of Kayak Skegs

E17 - THINKING AHEAD ON THE STITCH-AND-GLUE KAYAK - PETREL PLAY SG

0:00 Introduction and Overview
2:07 Removing End Pour Dams
2:27 Drilling Holes for Carrying Toggles
6:04 Removing Peel Ply from Fiberglassed Parts
10:04 Where to Get Good Paint Scrapers
11:07 Trimming Fiberglass from Parts
14:14 Marking and Drilling Holes for Skeg Control Knob
17:33 Drilling Holes in Skeg Control Box
20:17 Preparing Coaming Riser
22:54 Cleaning Up Coaming Riser Surface
25:23 Gluing Together Skeg Box
28:07 Mixing Epoxy for Filling Holes
30:09 Thickening Epoxy for Gluing Parts
32:31 Clamping Skeg Box and Letting it Cure
33:07 Gluing Coaming Lip to Riser
35:14 Changing Order of Operations

E18 - MAKING INTERIOR SYSTEMS - PETREL PLAY SG

00:00 Introduction and Overview
00:58 Installing the Skeg Box
03:07 Drilling the Control Knob
03:21 Rounding Skeg Box Edges
06:42 Inserting the Skeg Pivot Pin
07:59 Sanding the Skeg Box
08:36 Preparing the Skeg
10:54 Measuring and Drilling Holes
16:30 Shaping the Control Knob
18:46 Shaping the Cable Hook
19:04 Sanding the Control Knob
20:44 Glassing the Control Knob Slot
27:49 Concluding Remarks

E19 - INSTALLING THE SKEG BOX, CONTROL SLOT & CHEEK PLATES - PETREL PLAY SG

0:00 Intro and Overview
0:41 Installing Skeg Box and Control Slot
2:00 Preparing to Install Control Slot
3:28 Mounting Skeg Box Location
5:03 Skeg Box Cable Routing
6:04 Drilling Hole for Skeg Box
6:35 Cleaning and Prepping Skeg Box
7:54 Stitch Hole Locations on Skeg Box
8:10 Skeg Cable Entry Point
9:31 Drilling Hole for Barb Fitting
10:42 Marking and Cutting Skeg Box Opening
12:19 Fitting Skeg Box into Hull
13:04 Positioning and Clamping Skeg Box
13:37 Gluing Skeg Box in Place
15:01 Installing Control Slot
18:59 Applying Epoxy to Control Slot
19:52 Glassing Control Slot
21:01 Prepping Skeg Box for Glassing
22:03 Applying Fillet and Glassing Skeg Box
25:19 Installing Barb Fitting in the Skeg Box
26:05 Aligning Control Slot Tubes
27:12 Checking Alignment
28:05 Installing Cheek Plates
30:00 Glassing Cheek Plates
32:41 Completing Interior Systems

E20 - MATING THE DECK AND HULL - PETREL PLAY SG

0:00 Welcome to the Workshop
0:29 Preparing the Deck and Hull
2:11 Cleaning the Sheer Line
6:45 Sanding the Interior
10:31 Preparing the Hull
15:17 Joining the Deck and Hull
25:10 Leveraging the Tape Dispenser to Make a Tight Joint
34:03 Utilizing a Putty Knife To Fit a Misaligned Seam

E21 - PRECISION SEAM TAPING - PETREL PLAY SG

0:00 Introduction to the workshop
0:25 Preparing to run fiberglass tape
0:50 Sealing the seam with tape
1:58 Preparing the fiberglass tape
2:43 Laying out the fiberglass tape
6:22 Applying epoxy to the fiberglass tape
10:50 Unrolling and applying the fiberglass tape
16:07 Completing the fiberglass tape application
22:53 Wrapping up and looking ahead

E22 - PREPPING A KAYAK DECK FOR FIBERGLASS- PETREL PLAY SG

0:00 - Introduction and Context
0:24 - Preparing the Deck for Glassing
1:10 - Removing Tape and Rounding Edges
2:00 - Rounding Deck Chines and Joints
6:06 - Adjusting Deck-Hull Joint and Touching Up the Stain
10:13 - Rounding Cockpit Recess and Hatches
13:32 - Smoothing Ends and Creating Thumb Hole
16:13 - Sanding and Scuffing Deck-Hull Joint
19:07 - Adjusting Sharp Angles and Overhangs
27:23 - Refining Edges and Seams
36:05 - Final Surface Preparation

E23 - FIBERGLASSING THE DECK - PETREL PLAY SG

0:00 - Introduction
0:50 - Preparing the Skeg Control Slot
2:36 - Touching up Wood Stain
4:20 - Applying Protective Tape for Fiberglassing
5:58 - Mixing Epoxy and Fiberglass Application
15:05 - Challenges with Fiberglass Cloth Tension
19:23 - Resolving Fiberglass Wrinkles and Bridging
25:27 - Applying Fill-Coats and Trimming
32:19 - Installing Deck Combing and Clamping
38:39 - Outro and Additional Filling/Trimming

E24 - CLEANING UP CHINES AND EDGES - PETREL PLAY SG

0:00 - Introduction and Overview
0:23 - Explaining the Petrel Play Boat Kit
0:38 - Removing Masking Tape and Cleaning Deck
1:13 - Preparing the Combing for Glassing
3:50 - Removing Clamps and Cleaning the Combing
6:44 - Rounding Over Edges of the Combing
9:00 - Sanding and Feathering the Combing
11:07 - Addressing Bubbles and Imperfections
13:34 - Preparing Hatch Recess Area
18:54 - Sanding Deck and Combing
21:23 - Trimming Off Bottom of the Skeg Box
25:41 - Preparing Skeg Box Area
27:16 - Prepping Hull for More Glassing

E25 - THE WONDERS OF BIAS CUT GLASS - PETREL PLAY SG

0:00 - Introduction
1:02 - Preparing Fiberglass Strips For Difficult Shapes
5:04 - Cutting and Handling Bias Cut Strips
6:37 - Applying Fiberglass to the Combing
10:05 - Wrapping Fiberglass Cloth around the Combing
26:04 - Applying Fiberglass around the Skeg Box
31:00 - Future Plans for the Build
34:09 - Understanding the Video Series

E26 - SANDING AND LEVELING A STITCH-AND-GLUE KAYAK - PETREL PLAY SG

0:00 - Introduction and Fairing Overview
0:57 - Sanding and Leveling Process
6:03 - Dealing with Big Drips and Mighty Bumps
13:22 - Sanding the Boat Deck
22:37 - Preparing for the Fill Coat
27:26 - Sanding the Skeg Slot Area
35:02 - Masking and Preparing for Fill Coat
39:04 - Applying the Fill Coat Technique
45:03 - Wrapping Up and Next Steps

E27 - DECK HARDWARE - WHY DRILL HOLES IN A GOOD KAYAK? PLUS SANDING - PETREL PLAY SG

0:00 - Introduction and Overview
0:52 - Cleaning Up Drips from Previous Coat
4:46 - Sanding Process to Level Surface
16:32 - Achieving a Uniform Scratch Surface
23:13 - Prepping for Deck Lines Installation
27:46 - Drilling Holes for Deck Line Mounts

E28 - A BEAUTIFUL VARNISH FINISH DEPENDS ON PREP WORK - PETREL PLAY SG

0:00 - Introduction to Varnishing
0:21 - Sanding Material Preparation
10:03 - Finish Sanding Techniques and Tips
19:21 - Preparing for Varnishing
40:46 - Applying the Varnish Coat
51:23 - Varnishing Techniques and Reflections

E29 - THE LAST COAT: FINISH VARNISHING A STITCH AND GLUE KAYAK - PETREL PLAY SG

0:00 - Introduction and project context
1:34 - Preparing for final varnish coat
3:45 - Dealing with varnish drips and leveling
6:42 - Sanding techniques and considerations
11:00 - Preparing for varnish application
14:30 - Applying varnish to the deck
18:13 - Varnishing the hull
22:28 - Brushing techniques for beautiful varnishing
23:38 - Conclusion and next steps

E30 - INSTALLING HATCHES & BULKHEADS - PETREL PLAY SG

0:00 - Introduction and episode overview
0:52 - Preparing to install bulkheads and hatches
2:42 - Fitting the rear oval hatch ring
6:38 - Preparing the rear bulkhead
9:31 - Fitting the rear bulkhead
12:03 - Fitting the front bulkhead
16:55 - Installing bulkheads with epoxy fillets
22:22 - Gluing hatch rings with Gflex
30:37 - Conclusion and future steps

E31 - INSTALLING AND OUTFITTING - SKEG, SEAT, DECKLINES - PETREL PLAY SG

0:00 - Introduction to this Episode
0:53 - Installing the skeg control system
5:17 - Mounting the seat and backrest
18:52 - Installing kaykak foot pegs
22:23 - Creating deck lines and perimeter lines
33:45 - Installing the skeg mechanism

E32 - LAUNCHING OUR WOOD KAYAK - PETREL PLAY SG

Thanks for Watching and Happy Paddling