Lightweight carbon fibre sea kayak as light as 15.5kg finish
At Big Pond Kayaks, I take great pride in utilizing the traditional hand lay-up method for construct
Achieving a lightweight kayak using traditional hand lay techniques can be quite challenging, but I discovered an excellent product from Easy Composites: a hand lay epoxy. This allows me to apply the same methods I use for constructing polyester composite kayaks while achieving an ultra-light and durable finish. Weighing in at just 15.5 kg, I can now offer a lightweight option at an affordable price. By utilizing a combination of carbon fiber cloth, diolen, and epoxy on an epoxy compatible gel coat all sourced from the same supplier I maximize strength and build quality. I've already sent out a couple of carbon surge kayaks to clients, and the positive feedback has been incredibly rewarding, giving me a strong sense of accomplishment, and fully tested lightweight product.
Hand lay carbon fibre surge play model only £3995
Tradition vs innovation
What is hand lay up
I practice hand lay up techniques, utilizing only hand tools such as rollers, brushes, and scrapers to ensure a smooth process. I avoid vacuum bagging and infusion methods, which significantly reduces waste from materials like vacuum bags, infusion pipes, and peel ply that can quickly accumulate and harm the environment. By employing the hand lay up method, I maximize the use of materials, with minimal waste generated just a few pairs of gloves, a bit of acetone for cleaning brushes, and small off cuts from the edges of the molds. This approach allows me to manufacture my carbon kayaks in a nearly waste free manner.
Image to the left, hand made skeg box fitted to a hand lay hull all carbon fibre and epoxy on diolen and gel coat
Full control and care
My background as a traditional builder has equipped me with the skills to meticulously craft a kayak, ensuring that every component is placed with care and precision. I take pride in my work, and it’s impossible for me to leave anything unfinished or subpar; I strive to achieve the best possible outcome with each piece I create. I visualize every part of the kayak, dedicating time and patience to produce a remarkable final product. Nothing is left to chance, and I avoid the waste associated with machine-made parts, resulting in a stunning handmade kayak that often rivals manufactured products in its presentation and finish.
The finished kayak
I set out to create a super lightweight sea kayak that is cost effective, environmentally friendly, strong, and durable, all while boasting an attractive design. I believe I have successfully achieved this with a traditionally handcrafted kayak weighing just 15.5 kg. It combines modern aesthetics with a sporty feel, making it easy to lift onto your car or a long portage. While this project is still evolving, the feedback from the two owners who have taken the two iv made so far out on the water has been overwhelmingly positive. They have put the kayaks to the test, and it performs exactly as intended. Please take a look at the photos below.
Also see how i build one here on the link below