How to Build a Kevlar Canoe

Strongback & polystyrene strips

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Strongback is constructed of two 16 2x6s deck-screwed together in a T and mounted on sawhorses.  Each form is mounted to the top 2x6 with a 2x2 block (deckscrews again).  The bow and stern profile forms are screwed to the bow and stern forms and tapered.

The strips are cut from 4x8 sheets of 1 polystyrene insulation, angled at 8.  Each strip is then hot-glued to the form (use the short setting glue), then trimmed with a sharp filet knife to shape.  We used a random orbit sander to smooth out the high spots (and rough up the polystyrene for the next step).

 

All strips on ready for sanding down

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