Manual Assembly Kayak Assembly Accessories: MK II - 550 / 600

MANUAL
ASSEMBLY KAYAK
ASSEMBLY ACCESSORIES
MK II -550 / 600
MK II FORMOZA 550 SOF COMBAT
MK II FORMOZA 600 SOF COMBAT
WAYLAND FOLDING KAYAKS

Parcele Łomskie 15, 06 – 500 Mława , Poland tel./fax : (+48) (0) 503 875 547 www.wayland.com.pl e-mail : biuro@wayland.com.pl
LIST OF PARTS - MILITARY KAYAK MKII FORMOZA 550 COMBAT
PK1 – hull pcs1 DBP2 – side ladder front pcs2 K1 – snap fitting pcs 30 - 34
KWG2 – airsponson upper pcs 2 DBT2 – side ladder rear pcs 2 ZDB2 – sling side ladder pcs 2
KWGD2 – airsponson under pcs 2 WPP1 - deckbar front pcs 1 GWD14 –pole seat pcs 14
SP1 – keel (floor) front pcs1 WPT1 – deckbar rear pcs 1 KP1- clamp floor pcs 1
ST1 –keel (floor) rear pcs1 ZWDP1 – pole hook front pcs1 KB2 – clamp side ladder pcs 2
StD1 – wooden bow pcs1 ZWDT1 – pole hook rear pcs 1 ZTB1 – brekwater rim (bumerang)
StR – wooden stern pcs1 WDD2 –pole bottom front pcs 2 PP1- slider control peddals
W1 - rib 1 pcs1 WDR2 – pole bottom rear pcs 2
W2 - rib 2 pcs1 B1 – breakwater kit pcs 1
W3 - rib 3 pcs1
W4 - rib 4 pcs1
W5 - rib 5 pcs1
W6 - rib 6 pcs1
W7 - rib 7 pcs1

PLACE FOR KAYAK ASSEMBLY
It is necessary to get flat place free of natural obstacles like stones, roots etc to assembly the kayak properly.
It is very important for symmetrical and proper adjustment the frame inside the hull
3. ASSEMBLY
Expand and align the hull to make possible inserting of the frame.
Unfold front keel SP 1 and attach front stem StD1 by placing Ericcson nuts onto the alu brackets in the end of front keel SP1 (p. fot.2) and then
unclench the front keels rods and insert alu pins into proper holes placed in front of keel rods (p. fot.3.)

Front (rear) bottom poles WDD2 & WDR2 plug in proper short rods attached to the keel SP1 ZWD2 placed on stem and stern, by use of hooks screwed on the
ends of poles. Proper plug in of poles must be from the outside of stem (stern and rotating them to the center of boat. (p. fot.4,5) . Insert hooks into the brackets
ZWD in opposite direction to the final location and now rotate them of 180 to the boat center. Now insert poles into the rubber pole seats GP14 riveted on the ribs.
Rear floor keel ST1 must be prepared

analogously.
So prepared keels (front and rear) place along the hull properly in direction of bow and stern. Mount ribs W1 and W2 onto the front floor keel by placing snap fit-
tings L1 riveted on them on the suitable hooks riveted on the keel (p. fot.6) Ribs are supplied with numbers compatible to the numbers on keel.
Analogously ribs 6 and 7 attach

to the rear floor keel (p. fot.7)

Side ladders left / right must be now attached to the floor keels front and rear. Place the bracket located on the end of each ladder into the proper chink on the
alu slings ZDB2 riveted on the stem (blue) and stern (red). Now join side ladders to the ribs by use of special snap fittings riveted on the ribs and corresponding
hooks Zac2 on the ladders (see fot. 8, 9, 10, 11).

Mount deckbars front and rear WPP1 , WPT1. Place blue / red hook riveted on one end of deckbars into the due chink on the stem / stern sling. Second end
deckbar tongue into the snapp fitting riveted in the upper part of rib 2 (front) and rib 6 (rear) (see fot.12)
This way prepared kayak parts are ready to insert them into the hull. Now introduce integrated front frame into the
front part of hull and rear frame into the rear part of the hull. To perform this it is recommended to stand astride
over the hull in its central part and taking eg front part of frame and carefully insert it to the hull then repeat opera-
tion with the rear part of the frame (see fot.13)
Assemby must be performed symmetricaly. Airsponsons should be ideally located along the side ladders – it is
necessary to control it visually . It is most important for boat behave on the water.
Join both floor keels (front and rear) by use of alu clamp KP1 riveted on the front keel and corresponding
wooden block riveted on the rear floor keel. Lift up movable middle parts of keels then insert wooden block into
the clamp and move down keels by pressing carefully until they will parallel to the ground (see fot.14). (see
fot.14)
NOTE : Node must be still pressed to avoid serious injure when the springing keel releases itself

Now it is necessary to continue pressing onto the floor until the side ladders
are joined the same way. Insert wooden block riveted on the rear side ladder
into the clamp on front ladder and push it outside do the same with remaining
side ladder (see fot. 15)
Attach bottom central poles front and rear WDSP2 i WDST2. Insert their met-
al ends in the bushes on front and rear poles already attached to the stern
and stem. Now join them in the central part by use of movable bushes with
grooves fixed on the front central poles. (see fot. 17)

Assemble ribs W3, W4, W5 in proper places signed 3,4,5 on the keel central part. Ribs need to be joined by use of snap fittings on the corresponding hooks riveted
on the keel. Same way assemble ribs to the side ladders ( see fot. 16, 18) Bottom poles place in rubber pole seats riveted on ribs ( see fot. 18)
Assemble breakwater. T-shape hook GB1 insert to the groove in the tongue of front deckbar WPP1 and then close the connection rotating breakwater to the position
parallel with the boat axis. Go to the rear cockpit and join breakwater with rib W6 using fittings riveted on the breakwater ends and brackets on the rib W6 (see fot. 21)

Insert remaining T-shape hooks screwed on breakwaters across the corresponding steel eyelets on the upperdeck and then insert them to the locks on the ribs W3, W4 i
W5 and latch the locks pressing the lever.
Now insert the trimmed edge of cockpit into the groove in the upper side of breakwater (see pic 21)
Assemble breakwater rim ZTB1 (bumerang)
Now fill four airsponsons, symmetrically, by use of proper pipe valves on the sides of them. Filling of airsponsons must be alternately left side / right side / and again left
side / right side until the airsponsons are filled and reasonably stiff to get symmetry of the boat shape. Pressure inside the airsponsons should not exceed 1.2 ATM .
Mount seats. Unbuckle seats sets and pump airchambers included inside, depending on required height. There are two airchambers for seat and one for backrest. Now
place seats on the places with attached velcro types Velcro types attached to the floor and seats keep seats in stable position Now join seats side straps to the D-rings
mounted on the side ladders in corresponding position.
Now the kayak is ready for use
Disassembly must be performed in opposite way

Seats assembly
Open the seats. Unzip the zipper and unfold the seats.
Put seats on floor in destined places equipped with velcro type. There is corresponding
velcro type under the seat and on the floor of kayak.
Now fix hooks mounted on the strips attached to seats to the proper D rings fastened
on the strips on side ladders.
Adjust deviation of the backrest for your comfort position and pump three airbags which
fill inside the seats to adjust hight and hardness.
Now seats are ready for use.

Accessory assembly
Steering device and rudder assembly. Footrest assembly
1. RUDDER BLADE ASSEMBLY
Take the rudder blade and insert its bracket (part F shape with holes ) into the proper corresponding
support fixed on the hull stern. Fix it using metal L-shaped pin and passing it through the proper aligned
holes in bracket and support on the stern . Now turn around 90 deg the metal cotter to make pin secu-
red in its position.
2. STEERING PEDALS ASSEMBLY
Take control pedals and insert their doubled sliders nutts into destined sliders fixed on the floor. Adjust
position of the pedals accordingly to your requirements and tight the screws.
3. STEERING LINES ASSEMBLY
Steering lines are preliminary fixed to the rudder blade on ones ends. Take free ends of lines and
insert through holes in rubber breakwater and bumerang on cockpit rear rim. Now attach metal chains
to the pedals by use of stainless steel wire thimble. Adjust the pedals to be perpendiculary to ther floor
surface when steering lines are strained.
4. FOOTREST ASSEMBLY
Footrest fopr front paddler can be attached simmilar way

Spraydeck assembly
Take the spraydeck and put it on the breakwaters ac-

cordingly to its shape. First bond the horn of the
spraydeck by use of velcro attached on the rim and
spraydeck.
Now go to rear and tight the remaining end of spray-

deck on the rear wooden bumerang already fixed as a
breakwaters keystone, position holes in spraycover
with those in bumerang. Adjust the spraydeck, posi-
tion the spraycover flange with velcro align it oaround
the cockpit. Now force velcro connection around the
cockpit breakwater.
The main part of spraycover is now assembled. It ca-

me time to attch sprayskirts. First attach aluminium
riming on the spraydeck holes. Take it put on the hole
and roll the elastic flange around each rim then secu-
re it bu use of line passing each elastic flange. So
prepared riming allows to mount the sprayskirts. At-
tach sprayskirts rolling its edges on aluminium rims
inserted in elastic flange. Now the kayak is ready for
use.

Maintenance
Due to the quality of our products, Wayland kayaks can last very long when properly maintained. There are possible to be in service for 20 to 30 years.
Taking care accordingly to our recommendation you can keep your boat in service for many years. It depends on you of how long your pleasure with Wayland kayak will last. So be reasona-
ble using your boat and it will krevange to you delivering years of pleasure from kayaking
1. Storage
please always make sure that your kayak is clean and dry in its packing bags and that there is no sand left in it for short-term and particularly for long term storage. Choose a dry stor-
age place in house or garage or another place where moisture can not influent on the kayak.
When you are not able to take your kayak home dry so it is absolutely necessary that you get it dry before storage! - You can leave it assembled for some time to let the hull dry. When the
boat is dry and cleaned you can put it in bags again.
Never store a wet or dirty boat.

The kayak should never be in contact with cement floor or similar not breathing surfaces - use a breathing material like carton, PU foam matt or another to avoid esthetic faults on CSM hull
bottom. – Do not locate kayak in extremely cold or hot places and avoid longterm exposition to UVrays.
If you have enough space in disposal it is recommended to take boat out of bags and store the hull unrolled.
2.Handling and care
Check your boat after the season and preapare it for storage after use or a long exploitation. Clean it from sand, stones, organic pollution, twig or by use of mellow sponge, towel or brush.
For cleaning the hull or the wooden frame parts use only fresh water and a usual soap.
Avoid use of grease or chemicals, oils or unknown substanhces. Never use detergents
For best effects of maintenance use original WAYLAND products. The transparent Wayland boatpolish liquid for rubber conservation would be the best choice. Apply thin layer using a soft
cloth to cork the microholes in the hull bottom. This intervention is recommended at least one a year. It is also available special boatpowder which allows to keep boat hull rubber parts elas-
tic and flabby.

Care of Wooden Frame Parts : Sun, salt, sand and organic pollution or rubbing can affect adverse the varnish on wooden frame parts.
For repairs of wooden frame parts use our varnishes combination only for marine application. To cover wooden surface by varnish you must be sure that it is dry and clean. Use sandpaper of
80 grad to remove damaged layers of old varnish or pollutions. Cover cleaned and dry surface with a thin layer of varnish by use of a brush. Then leave it to dry. Avoid sunlight or hot condition
to eliminate bubbles. Repeat this and decide when the surface is well painted.
Transportation
Packing system 1, 2 or 3- partial makes stansport easy and comfortable. Kayak can be successfully transported by car , plane or train and even by bicycle when using destined trailer.
It is possible also to transport boat assembled on car luggage rack. We recommend to use soft mat under it in this case to avoid car varnish damages. Tight the boat with belts, and try to
keep front part lower then rear one not to disturb vehicle aerodynamics.
Fittings removal and exchange

A WAYLAND kayaks are customer-friendly. All repairs necessary for kayak to stay in service are possible by owner to perform. All wooden parts are joined each to other by alu rivets or
screwed. They can be easly disjoined if necessary or in case of connection damage and repaired by replacing rivet or screw and damaged fitting exchanging to new , orginal Wayland one.
Keelstrips
Longterm hard exploitation may effect damages, abrasion and scars of hull bottom. To avoid or reduce this damages keelstrips assembly is strongly recommended. If the kayak gets damag-
es , holes or scars on hull bottom so it can be repaired by attaching the patches from repair kit. There you can find all equipment for this operation. All expedition and Quattro models are stand-
ardly equipped with combination of keelstrips.


Manual Assembly Kayak Assembly Accessories: MK II - 550 / 600

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MANUAL

MK II FORMOZA 600 SOF COMBAT

WAYLAND FOLDING KAYAKS

W1 - rib 1 pcs1 WDR2 – pole bottom rear pcs 2

W2 - rib 2 pcs1 B1 – breakwater kit pcs 1

WAYLAND FOLDING KAYAKS

WAYLAND FOLDING KAYAKS

Rear floor keel ST1 must be prepared

Analogously ribs 6 and 7 attach

WAYLAND FOLDING KAYAKS

WAYLAND FOLDING KAYAKS

WAYLAND FOLDING KAYAKS

WAYLAND FOLDING KAYAKS

WAYLAND FOLDING KAYAKS

Assemble breakwater rim ZTB1 (bumerang)

Now the kayak is ready for use

Disassembly must be performed in opposite way

WAYLAND FOLDING KAYAKS

Now seats are ready for use.

WAYLAND FOLDING KAYAKS

Steering device and rudder assembly. Footrest assembly

1. RUDDER BLADE ASSEMBLY

2. STEERING PEDALS ASSEMBLY

3. STEERING LINES ASSEMBLY

Footrest fopr front paddler can be attached simmilar way

WAYLAND FOLDING KAYAKS

Take the spraydeck and put it on the breakwaters ac-

Now go to rear and tight the remaining end of spray-

The main part of spraycover is now assembled. It ca-

WAYLAND FOLDING KAYAKS

Never store a wet or dirty boat.

2.Handling and care

WAYLAND FOLDING KAYAKS

Fittings removal and exchange

WAYLAND FOLDING KAYAKS

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