Construction Steps
Layout Preparation /
Specification Check
Wave
Dancer Productions begins each kayak with a blueprint from Chesapeake Light
Craft. The sales team sends over to
the kayak shop any personalization or customization that the customer requests.
The boat master goes over the plans and any new specifications to ensure
that all the details work properly and that we have the entire customer’s
needs met. If there are any
questions the boat master will contact the retail store first and then the
customer for further clarification.
Hull Preparation
Shop personnel receive the final plans and begin to cut
out wooded blanks that form the hull and bulkheads.
These hull pieces and bulkheads are wired together to form the bottom of
the kayak. Each seam is sealed with
a wood fiber resin mixture.
The
kayak is flipped over after the hull has cured. The wires are removed and the
hull is sanded smooth to accept the fiberglass cloth that is applied to the
kayak. The cloth is filled with
clear epoxy resin, then sanded smooth.
Deck
Preparation
The
kayak is turned over to sand the interior and fit in any additional option to
personalize the kayak. Shear
clamps, which run along the inner-side of the kayak, are formed to accept the
deck material. After the deck is applied it is sanded smooth with extra care
to bring out the exceptional grain of the wood.
The deck is covered with fiberglass cloth, which is also filled with a
clear epoxy resin. The kayak
receives several sanding applications to remove any imperfections.
Painting / Varnishing
Wave
Dancer Productions take great pains to make sure that the final finish is immaculate. The hull receives a
primer layer, which is then covered with a two-part polyurethane.
The hull is highly resistant to abrasions with this coating.
The deck is coated with a marine varnish to protect the kayak from UV
rays. The deck rigging is applied
and any custom painting is completed. The
boat master inspects each kayak at every step to ensure quality. When the boat master gives his final approval the kayak is
wrapped for shipment.
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