ot entirely related to this Serene – 2 building, but I would want re – organize my woodworking workshop a bit. My working place is quite small in floor area, so everything need to be stored neatly and tidily. Having quit some ideas, but would carry them out only one at a time, since I still have limited free time in the present. First is a shelf to store my plywood and MDF sheets (lots of them), and many other things.

The plywood and MDF sheets need special treatments, they could deform in shape or absorb moisture if stored inappropriately for a long time. The shelf would have two sides, the sloping side is for storing the sheets, and the other side is reserved for other things. The whole thing would be put on 6 small wheels so that it can be pulled and repositioned around the workshop, or moved just for cleaning the floor.

1^st image: making the shelf base, 2^nd image: the 3 supporting walls (to withstand the MDF and ply sheets’ weight, which could be very heavy). 3^rd image: the shelf taking shape, 4^th image: the completed and marine – blue painted product, ply and MDF sheets stored on one side (facing the wall). I need lots of shelf spaces to store various miscellaneous assets, which is growing to a unmanageable number 😢.

Sometime, I’ve forgotten that I’ve purchased something just because there’s a huge pile of them around. The workshop looks very tidy now, having more spaces to store various things. It’s very important to keep thing tidy, uncluttered, as you wouldn’t want to waste time finding an item when needed. It’s now time to move on to the main parts of the project, I’ve been lingering around on other issues for long enough.

irst image: assembling the rudder’s components, the rudder in its dropped down position, 2^nd image: the rudder in its retracted position. Everything works smoothly as calculated, the blade could be pulled up and down by a pair of line running back to behind the cockpit (but that would be done later, when attaching the rudder to the kayak hull), with two circular ratchets glued on the two side of the rudder blade.

4^th image: the rudder stained with colored – epoxy and then painted (with transparent PU – PolyUrethane). It looks so nice, the dark brown color with coarse wooden grains 😀. The rudder control system is another complex problem, but that I would address it later on on the following phases of this building project, as I’m still hesitating between the two styles of rudder steering mechanisms as described below.

One style is the T – bar of those Olympic kayak, and the other is the normal 2 – pedals usually found on touring boats. The Olympic style is simpler, but it’s quite counter – intuitive as you would have to use the left leg kicking the bar to the right, in order for the boat to turn right. The 2 – pedals system is more user – friendly, you simply kick with the right leg to turn right. I also may use kind of a cross between the two mechanisms.

This is the first time I use a rudder, so many consideration and calculation have to be made. First in designing the hull, the hull should work efficiently and independently without a rudder, that is, it should track straight in most circumstances. Only under extreme turbulences that the rudder should be deployed, to save yourself from the extreme fatigue of one side paddling, or to have more responsiveness to the moving water.

keg, rudder or none!? It has always been an everlasting debate among the sea kayaker community. Some advocates using none, as getting the job done with your paddles alone would greatly improves your skills. While I partially agree to this argument, I also think that the argument only holds true on flat water only. When in turbulences, which could be extreme, you would need something to assist in tracking and steering the boat.

All my previous kayaks was using skegs. While a skeg wouldn’t help in steering, it would help a lot keeping the boat on a straight track when underway. Gradually, and especially in my last 9 – days trip, I realize that a rudder could potentially become a great benefit. You could pull it up to reduce drag (with a retractable rudder) and maneuver the boat with your paddle alone when it’s relatively calm, and deploy it down in turbulences.

Not only it helps turning your boat to compensate leeway, it’s also a way to have instant responsiveness, e.g: to deal with large chasing waves. So I decided to overcome my fear of complexity and build a rudder for my next Serene – 2 kayak. Yet, complexity is the reason most pro – skeg paddlers would give, to justify their favor for skeg. But serious sea – paddlers would agree, I think, that rudder outperforms skeg in most situations.

It’s not too complex (as it seems) to draft out the rudder’s parts on wood. 1^st image: elements of the rudder, 2^nd and 3^rd images: gluing them together. 4^th image: the rudder blade is (like they usually call) a high – aspect – ratio foil, 10 x 50 cm in dimensions. The 2 circular discs: ratchets for pulling the blade up and down. Now, I definitely think I could build a rudder that would work, both efficiently and reliably! 😀

he structure of the hatches is nothing fancy, three tight rings nested inside each other per hatch, two belongs to the lid, and the other would be attached to the base (deck). First image: the 9 rings forming 3 hatches, filled with some thinned epoxy (about 400 gram of epoxy) to harden the MDF. This is not a very good way to make hatches (weight wise), but it would be just as heavy (or lighter) compared to plastic ones.

I was thinking a lot about the hatch locking mechanism. But finally decided to just use cords and cleats to tie down the hatches. The metal locks are too complex and fragile, unendurable to salt water. Tying down the hatches is much simpler and secured, and is easy to repair when something breaks. Between the 2 rings of the lid is a thin layer (about 3 mm) of epoxy (the softer, elastic kind) filled in to function as a gasket.

At first, I intended to glass in and out of each of the hatches’ rings, but the 9 mm – thick MDF walls have absorbed enough epoxy, and have become really strong (maybe more than enough, they’re now a bit too heavy 😢), so there’s no need for glassing. The good thing is that once everything is assembled together, they fit very tightly, the lids and the bases, and the dark brown color is stained nicely too!

3^rd image: the complete products, lids opened, 4^th image: the lids closed. Once I’ll finish building up the kayak’s deck, the hatches would simply be glued on. Only the front hatch needs some special treatments, as the front deck is curved in shape. Also, the compass would be mounted right on this front hatch lid, to save deck space, and to simplify the building process. But that would be another later phase of this project.

ad a major setback with making the hatches with wooden strips, the strips didn’t make perfect circles as I’ve expected, although they bend quite well, they’re off by small amount (e.g: 0.5 ~ 1 mm) here and there, and that’s an unacceptable precision for hatches, just a small gap and water could leak in. I had to abandon the method of making hatches using wooden strips, and tried to find some alternative ways instead 😢.

Finally, I resorted to cutting the hatches’ rings (lips) using my routing table. The home – built machine is made quite a long time ago, but this is only the first time making some serious use of it. It’s quick to make a circular cutting jig, as shown in the 1^st image: the MDF “disc” would rotate around a pivot point that could be adjusted by sliding the wooden bar. The jig proved to offer good cutting accuracy (sub millimeter).

That’s really good, as I want very tight fits between the hatches’ rings, 3^rd image: 2 rings cut, there’re still lots of it to be made. Using solid MDF as hatches’ rings has a serious down side: you would need to fill the MDF with much epoxy for it to be hardened, and waterproof, thus increasing the overall weight. On the other side, MDF is easy to cut into perfect shapes! Decided to go this way anyhow as I have few material choices!

Last image: all the hatches’ rings is cut, 3 hatches, 3 lips per hatch, and 2 rings per lip (since they’re cut in 1.5 cm MDF, it requires 2 rings to form a 3 cm height lip), quite some work to be done, and too much of sawing dust too 😢! And I’ve taken care on “quality assurance” to make sure that each ring is cut at its precise diameter. Though I don’t expect the hatches to be waterproof, it should be watertight as much as possible.

‘ve been thinking about kayak hatches over and over again. Starting from the very early days with my plywood hatches (in Hello World – 2, 3) which are obviously not watertight, to the Beckson hatches on my Serene – 1 kayak. The Beckson is very good, watertight and even air tight, but sadly that’s only true in ideal conditions. In reality, in multiple days trip, when mud and sand has get into, it would leak by a small amount.

The Beckson is not ideal hatch for kayak in my idea (for other purposes, it may be ok). The reason is that the hatches are built flushed with the mounting surface, and some inner elements are even recessed… When the water washes over (as always happened to the very low freeboard of a sea kayak), and when the O – rings are not properly lubricated, or when there’re some mud, sand inside the joints, water would leak in.

That’s why I decided to build my own hatches for this Serene – 2 new kayak. The idea is really simple: the hatches are raised a few centimeters above the mounting surface, and even when the seals are not too tight, that would suffice to keep most of the water out. Examine many sea kayak hatch designs, I’ve found out that simple thing, that the hatches should be raised (not flushed or recessed) above the deck.

1^st image: cutting thin (2.5 mm) wooden strips used to build the hatches. 2^nd, 3^nd images: the 3 MDF templates for hatch building: the rear, the front and the day hatch, sizes in diameter: 30, 25 and 20 cm respectively. 4^th image: building the hatches’ coaming with thin wooden strips around the templates, each coaming consists of 2 layers of strips which bend easily around without cracks and without the need for steaming.

inished with Serene – 2‘s first paddle, continue to the second one. This would be the pair of paddles, one Greenland style, and one Euro style, that I would use on the new kayak, intended to be slightly smaller in size, and much more lightweight compared to my previous ones. The Greenland paddle is not a typical Greenland one, it’s rather quite short with bigger blades, and the Euro paddle is not of typical Euro style neither 😀.

As it is quite small compared to most Euro style paddles. It’s quite hard to justify my design decisions, but all came from my paddling experiences, that I would need a slightly bigger Greenland paddle for all – round paddling, and a slightly smaller Euro paddle to provide more power in “adversary” conditions. The second one would be lightly & simply built also, with that same kind of rattan shaft, and thin plywood blades.

1^st image: the finished Greenland paddle. 2^nd image: dry fitting the Euro paddle’s blades and shaft. 3^th image: bending the plywood blades, I want them to be just slightly curved around the longitudinal axis, it’s just nearly impossible to bend the plywood around multiple axes, to decided to stay with the simplest blade design. After gluing the blades and shaft together, the paddle would receive a layer of fiberglass all around.

4^th image: glassing the second paddle, next to it is the finished Greenland paddle, the pair of paddles near completion, they all need to be “trialled” soon, to evaluate their performances, and to see how they would behave in real world. Final weights, the Greenland paddle: 0.82 kg, the Euro paddle: 0.9 kg, not up to the “standards” yet, but quite near, that’s fine anyhow, as they’re very light (compared to my previous paddles) 😀.