This kayak weighs less than 40 pounds and will carry a full-sized man. It is constructed of plywood, canvas, and wood strips - all held together with contact cement! The design is for a 10-foot kayak, but 8-, 12-, and 14-foot versions have been successful. The boys build the kayaks as a group, with adult supervision. Most of the materials needed for construction are purchased by the Troop as a bulk order at the lowest price available. Paint and sandpaper are bought on an individual basis. First, the plywood is cut into the body panels, the spreader boards are cut and shaped, and all of the remaining parts are cut out. The body panels will be given to the boys a week or two before the group session.
Before the group session, the boy must complete sanding and painting the inside surfaces of the ody panels, as they become inaccessible when the kayak is glued together. The wood panels become a kayak on the group session when they are glued together with contact cement and canvas strips. Finally, all of the reinforcing wood strips and boards are glued and bolted into their proper place to complete the kayak. The paddles and seats are also finished. All that remains is for the scout to paint the kayak with a scheme of his choice and to prepare for the thrill of paddling his own boat for the first time! The final painting is done by the scout at home. About thirty scout (and parent) hours are needed to complete a kayak.
The cost has grown through the years. In 1980 the cost for troop provided supplies was about $60. In 2000 the cost was $115. Prepayment for materials is requested before the bulk order is placed.