The Ultimate Downwind Machine: Designing and Building the "Runner" Kayak
Nick, a boat designer and builder, embarks on creating his "coolest kayak yet"—a 17-foot sea kayak named "Runner." He begins by outlining his design goals, emphasizing the desire for a kayak that excels in downwind conditions and surfing, inspired by the waves in Long Island Sound. Drawing inspiration from his previous design, the microBootlegger Sport, Nick meticulously details the modifications he made to achieve his performance objectives, including lengthening the hull, narrowing the width, and strategically shifting volume for optimal lift and maneuverability while surfing. He incorporates features like a rudder, a squared-off bow, and self-draining hatches.
The building process starts with translating the 3D design into physical forms, using leftover mahogany and Alaskan yellow cedar strips. Nick explains his decision to use a staple-less approach for the mahogany, opting for hot melt glue to secure the strips to the forms. He highlights the challenges of working with different wood thicknesses and the need to carefully align the grain for a visually appealing result. Nick also emphasizes the importance of fitting each piece individually, showcasing the unique nature of boat woodworking.
Throughout the build, Nick shares insights into techniques for achieving a smooth and fair hull. He demonstrates how to create a temporary fence for routing a consistent groove along the keel line, simplifying the process of fitting strips. He also addresses the intricacies of strip planking the deck, splitting strips to accommodate the rounded shape of the stern. Nick's attention to detail is evident as he meticulously tapers strips and uses filler pieces to ensure tight joints and a seamless appearance.
After planking the hull and deck, Nick explains the process of releasing the hull from the forms, breaking the hot melt glue bonds. He then details the careful steps involved in joining the deck and hull, using small wooden bridges to bind the two sections together while maintaining their independent flexibility. He further enhances the deck's aesthetic appeal by incorporating thin curly maple accent strips and meticulously tapering them for a seamless blend with the surrounding mahogany.
Nick acknowledges that the video doesn't capture every stage of the build, but emphasizes that he covers these steps in detail in other videos and books. He highlights the extensive fairing and sanding process, the use of Baltic birch plywood for hatch recesses, and the reinforcement of the interior with carbon fiber and fiberglass. Nick also shows the creation of the skeg control slot, the rudder control cables, and the installation of deck line fittings.
In the final stages, Nick focuses on achieving a perfectly level part line and installing a flush-mounted compass with a custom-made dome for a watertight seal. After the interior work is complete, the deck is bonded back to the hull, followed by more sanding and a professional automotive clear coat finish. The video concludes with Nick showcasing the stunning "Runner" kayak, highlighting its elegant design and impressive performance on the water.