WOT: Dad's kevlar canoe major repair/rebuild, Any kevlar repair guru's? A few questions Options

[Mark Henry]

Over the winter I'd like to repair my dad's canoe. I know it looks bad, but the main skin is kevlar, the woodwork is cedar and fairly simple, plus there is enough bits to copy. I have the tools, my trade is cabinetmaking. Only thing missing to copy is the yoke, but the old one sucked anyways

The kevlar repairs will be the only thing hard-ish to do and this is where the question comes in....
Can I cut this in half and add 3 feet to the center?

It's a 15-1/2' canoe and it's looking like I need a 3 person canoe. If the wife was into it I'd get another canoe, but if it's just me and the 2 kids I'd rather have just one canoe. Most 3 person canoes are 18-19 feet.

Any tips would be welcome (IMG:style_emoticons/default/smile.gif)

[Mike Bellis]

Kevlar is almost like fiberglass and uses the same techniques. I would be a little concerned with the structural integrity after adding 3 feet..

That is probably a vacuum molded product. Very hard to duplicate in the garage. You could build a buck and layer it on old school style. It will not be as smooth or as thin but should work.

How concerned with looks are you?

[914forme]

Kevlar is almost like fiberglass and uses the same techniques. I would be a little concerned with the structural integrity after adding 3 feet..

That is probably a vacuum molded product. Very hard to duplicate in the garage. You could build a buck and layer it on old school style. It will not be as smooth or as thin but should work.

How concerned with looks are you?

You can vacuum mold in your garage, and it is recommended with Kevlar to get the epoxy resin into the weave. BTW, Epoxy is nasty stuff. It will take a large bag, and a good pump.

I would lay it up on the inside then bridge the gap. Add structure to tie it all together, then spray new gel coat on the outside. Then spray wax on the outsdie of the gel coat. The wax will actually protect it and allow it to cure properly. You can then buff it out.

If you skip the wax, it will not cure for almost the entire season. Did a jetski once, and learned th hard way. (IMG:style_emoticons/default/headbang.gif) Once it has cure you can buff it to a super gloss shine.

Option #2 is use the existing shell as a form, wax the shell and make it your plug. You could then make it out of carbon fiber use a clear gel coat, and have a ricer canoe. Just need a few stickers, and a fart can.