Counting the cost

November,  2015

In case you have not been following along I just finished building a new kayak and I kept close track of the costs and the labor to build it. My wife finally tried  kayaking and discovered just how much fun it can be. Problem was, none of the boats in my stable really suited her, so I needed to build her one..

Short Shot has always been an under appreciate design.  At sixteen and half feet and with better resistance numbers than most of my designs I had expected great things from this design but sales were always slow at best. I felt the styling was part of the problem and I have long thought about redesigning it to look more traditional and this was the motivation I needed.

ss-24As I built Short Shot, I kept close tabs on the time and cost of this boat. I had a lot of scrap plywood and other odds in ends in the shop from other projects I had saved, so my cost to build wouldn’t reflect your cost. Instead of keeping tack of what I spent, I kept track of all the materials and prices for these items. The following is a list of what it took to build this boat.

16.5′ Short Shot kayak Fully
loaded
Minimally equipped
Materials Cost Cost
Plans $      69.00 $           69.00
Plywood for frames $      50.00 $           50.00
Western red cedar for stringers  $     25.00 $           25.00
Sinew-2 rolls $      19.00 $           19.00
Paint 2 quarts and 1 pint, Rustolem $      27.91 $          23.00
2 quarts
2 can spray poly $      21.90
Sewing thread $        9.00
18 feet of 11.7 oz fabric $     126.00 $          81.00
8 oz fabric
Seat $       86.00
Paint supplies $       21.00 $           21.00
Brass 5 feet $       30.00
Bungee 17 feet $         5.95 $             5.95
Backband $       28.00 $           28.00
Black rope $         6.40
Stainless screws for coaming (box-50) $         8.25 $             8.25
TOTAL $     533.41 $         330.20

In the first column is what I used to build the boat. It included a Redfish seat, brass strips on both ends, the 11.7 oz skin and deck rigging. We stained the frame to enhance the look and then we coated it with gloss poly. She wanted a two tone paint job with a black stripe, so that took 3 cans of paint. All this came to just under $550. When you consider this is a 34-35 lb kayak that is not a lot of money! You can’t buy a used composite boat of similar weight  for that.

A lot of people are attracted to these boats because of the low cost.  I wanted to see what the low end would be so I created a column with just the minimum parts. No stain or poly on the frame, no Redfish seat, using sinew instead of sewing thread, etc. By cutting out the extras you could build this boat for $330. With a little care I think you could come in  under $300.

You will pay almost that much for those 10′ or 11′ kayak all the big box stores sell. The difference is any of  my designs will be far easier to paddle and much faster! Yes there is a big difference and it is not the weight of the boat. I don’t design short boats because short boats are barges. There is no way around that either, but that is another story for another day.

And these are not a boat with a 2-3 year life. As long as you take reasonable care and don’t store in the sun or where it will stay wet and rot, your can probably pass it on to you kids or grand kids.

I also kept track of the labor to build Short Shot.  I feel it only fair to point out that I have built a few boats ,so I have the process down and don’t have to spend time thinking about what or how to do something. I have done it enough that it is just instinct, so I am going to be able to build one faster than most people, especially if it is your first time. But the learning curve is short and most people will be able to get reasonable close to these numbers.

Task Task Hours Total Hours
Cutting frames 8:00 8:00
Setting up strongback/cutting – scarfing – gluing stringers 2:43 10:43
Lashing 1:21 12:04
lashing 3:44 15:48
lashing 1:17 17:05
lashing 4:52 21:57
lashing-FINISHED 4:52 26:49
Staining frame 2:23 29:12
Spraying poly on frame-paint coaming 1:00 30:12
Skinning 2:00 32:12
Skinning 1:36 33:48
Skinning 4:20 38:08
Installing coming 0:54 39:02
Painting 1:15 40:17
Painting 1:30 41:47
Painting 1:12 42:59
rigging 3:18 46:17

As you can see I spent just under 46 and 1/2 hours, start to finish on this boat.  In my classes we build a single chine boat, VARDO or Ravenswood in roughly 45 hours and these are typically people who have never built a boat or much else in their life. Short Shot is a multi-chine boat and that takes a little longer to lash all those stringers. I have people tell me quite regular that spend about 60 hours on their boat and this seems like a reasonable number to me.

As I said earlier, I don’t do short boats because they are not good designs. White water boats get away with the short lengths because of the ways they are used. They are pushed along with the current and not paddled long distances on flat water, so the high resistance is not an a problem. But if you are looking for sea kayak to paddle on open flat water you need a little waterline length.

Drop in my web site and check out my designs. Kudzucraft
Talk to people who have built and paddle my boats on our forum.

ss-27

 

 

 

Building Short Shot – part 8- launching

She is finally done and Launch day finally arrived. I hated that it took at least 3 weeks longer than it should have to get it finished, But a nasty sinus infection that took two rounds on antibiotics kept me out of the shop. This is my wife’s new boat and I was trying hard to get it done in time for her to take it for a paddle. But the weather turned cold and so did the water. She is not ready (or willing) to paddle in the cold so unfortunately she will not get to paddle it till next year.

Since the last update I have installed the bronze rub strips, deck bungee and perimeter lines. All of these are pretty basic items but very essential! The color combination was my wife’s and I think it came out really nice.

We took it to the ramp near our house to get some and make a brief paddle. First thing I noticed was the volume. Compared to Shad and Sling Shot, which I paddle most of the time, it seemed quite large. It is not really, it is just those are small boats compared to this one. After adjusting to its size it was actually quite comfortable. Back band feel at a perfect height, new coaming design was very comfortable and despite higher volume, I didn’t bang the paddle as I expected.

Second thing I notice was how quick it turned at low speeds. This is the difference in hard chines and the multi-chines shape. This hull has no abrupt corner and water seems to slide under the hull much easier. The difference was very noticeable! Leaning the boat to turn it felt much different than the hard chine boats. It’s hard to explain but it felt safer and like I could lean a lot more before it would capsize. But I didn’t test that, even in my drysuit I really didn’t want to swim.

I only paddled it around for maybe an hour but I liked it. Past that I will hold off on any judgments till I spend more time in it. We will see if it has any bad habits that hasn’t let me see yet.

ss-25 ss-24 ss-27 ss-26Now for some totals. Labor ended up at  46 hours 17 minutes, Of course I have built a lot of these so you should expect to spend a bit more than that.

Materials were $526.16 Keep in mind This is for a well equipped boat. Not cutting any corners on this boat or wasting any money on unneeded items either.

I am going to do another blog and break down the costs and talk about some of my choices for this boat. Mean time I can tell you I did some quick figuring and by skipping some of the items like the Redfish Seat, brass rub strips, etc. you could cut the cost down to under $350.

 

 

 

Building Short Shot – Part 5 – Skinning

I am at least a week and  a  half behind on this project. Yet another sinus infection has stolen any strength or will to work I have had. Today was the first time in well over a week I have been able to be productive. I have gotten in an hour here and 30 minutes there, but you don’t get much accomplished that way.

As of tonight I have about 75% of the skinning completed. I am using the Double Corded stitch with the 11.7 oz fabric. This has become my go-to fabric/stitch combo. As I have said before, the fabric is a little stiff and a little hard to get the needle through but the weave is so tight you can really pull it tight around the frame.

ss-17I ended the stitching by just wrapping it around the end of the boat so that is just out of sight. Sorry, I didn’t get a photo. On the ends I trim the fabric and staple it in place with stainless staples.  This will all be covered the with bronze rub strip (stemband) screwed in place. ss-14Because the fabric has such a tight weave I was able to try something new. I laced the fabric inside the coaming and then pulled it tight. I could easily over tighten it and deform the lower coaming ring so I clamped the top ring of the coaming in place and then tightened it. With it tight, I could how everything fits and if I have any problems.

ss-15The only problem I have is some wrinkles at the back corner. This fabric doesn’t shrink like the 8 oz. does, so I want to keep wrinkles to an absolute minimum. These shouldn’t be a problem.  What I can’t pull out I should be able to shrink.

ss-16

Here she is when I quit. Assuming no relapse of my sinuses I expect to finish skinning tomorrow.ss-18

I wanted to post my chart of the time and cost so far.  I still have to adjust a couple of the cost figures, so this will change a little bit. But the time stands at 37 hours so far.  I expect to be in the low 50’s when all is said and done.

ss-19

Rounding the corner

As the title implies, it feels like I have rounded the corner when I get to this point.

First order of business was to go back and relash a couple of stringers. This photo is probably a bit confusing but you are looking at the end of the sliding seat unit resting on the frame. The unit is resting on the lashing. Taking it in and out is would eventually wear out the lashings so I needed to fix it…. or rather fix all 6 of them.

The fix was simple enough. Just cut a notch in the frame for the lashing to rest in and that would keep it out-of-the-way.  Then lash the stringer with an H lashing.

With that done the frame is finished and it’s time to apply the oil. This is not one of my favorite jobs but I do love watching the wood change as the oil is applied! I love the look of oiled WRC.

I have finished the outriggers, I am just waiting on the hardware to arrives so I can mount them to the frame. I oiled the outriggers and seat frame.

Once I get everything fitted and I will apply the varnish. I was going to varnish now, but I had second thoughts and decided to wait.

Once the oil has had a couple of days to dry it will be ready to start skinning. Next I need to  building a set of oars. For the first time I feel like I can see the end of this project. There is still a lot left to do but it feels like it is getting close.

And this one is JUST RIGHT

Outriggers are done, well as far as I can go right now. They are still held in place with some F-clamps so I need to order hardware.  I think I will start sanding and varnishing everything next. It might get skinned up a little but I can touch it up before I do the final assembly.

It is supposed to be stormy but since the storms are not here, I decided to take some  FROG photos (Frame On Grass).  Looking at it the outriggers look sort of narrow but they are correct for a set of 8 foot long oars. I wanted to start with these and see what I have built. If I don’t have any problems and decide later I want to try some 9′ oars, it’s just a matter of building a new set of outriggers and bolting them on to the frame.

Small fix for a big problem

As the title implies the fix was simple. Finding it. not so much.

If you look at the end of the keel stringer (boat is upside down in the photo) you will see I added a small block of plywood to the frame. Believe it or not, that made the boat assume a proper shape. Not exactly as I had designed it but it has some rocker in it now. I did find something else that was working against me, but it wasn’t worth the effort it would take to fix it.  Bottom line is I know what I did wrong and how to fix it.

So the frame is done as far as I can tell. It’s stiffer and while not exactly the way I designed it. I am happy with it.  Now it’s time to finish the outriggers for the sliding seat.

 

 

Frame is done and we have a problem…

Frame came off the strong back and I took out in the yard for the obligatory F.R.O.G. photo. (frame on the grass)  I still love that raked transom.

I took it back into the shop and placed it on the trailer just to get it out of way so I can clean up around the stands.

I noticed there was more flex in this frame but there is also more wood, so it is heavier and skinning always stiffens them somewhat so it wasn’t a big deal. Then I was on the other side of the shop, turned around and I could see the frame was hogged. No doubt about it, the bow was lower than the center of the boat. I could not  believe it! I took and string and tied it to the boat stretched it along the keel, found that the bow was 1″  lower than the center of the boat.

After a lot of double checking and measuring I still didn’t have an answer, just a couple of ideas. After removing a few lashing, forcing the boat back in shape and studying why it wanted to deform when the pressure was released I have found a couple of reason I suspect are behind this. Of course there is only one way to find out, but that is for the next post.

Still plugging along

Have not made much progress but I am really close to taking the frame off the strongback. Between the ankle and other things going on I just have not gotten to spend the time on this project I really wanted too. But today I finished lashing everything but the deck beams. I needed to scarf some of the cutoffs together to get the lengths I needed for the deck.

Really anxious to get it off the strongback and flipped over. It’s going to make fitting the transom much easier. Here is a couple of photos. This is a one long boat!

 

New boats, new products

Had a little accident early this week and took a pretty good fall.  Fortunately (and amazingly) I just have a bruise and sprained ankle. Not being able to get in the shop I work I have had time to finish up a few projects.

I just listed some new designs and a placed a couple of new items in the store.

My first tandem canoe, Tangerine.  16′ long is now available.

Crawfish Pirogue’s are also available.  These are all about being simple to build. Not that they can get a lot simpler than they were though.  I am thinking this could be great Boys Club or Scout projects. Father and son/daughter building project.  There is a single and a tandem version.

Also, I now have a black marine grade bungee cord and a black polyester rope for making life lines now available in the store.  They actually will not be in stock till end of next week but I went ahead and listed them.


If there is something I don’t offer let me know and I will look into it. I am looking into some other items and I do have a couple of boats designs in the works.

Jeff