Professional Documents
Culture Documents
Rev 00 – 02/10/07
JEM Watercraft
Like all watercraft, if used improperly, serious injury or even death could be the result. It is the
builder’s responsibility to build the boat properly and to acquire the necessary skills for safe
JEM Watercraft - Free Canoe Plans
recreational use. In other words: Be smart, wear your PFD, use good judgment, and have fun!
Read these instructions start to finish at least once before you purchase
materials, draw, or cut anything to ensure you’re familiar with the entire process.
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These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
JEM
• Watercraft - Free Canoe Plans
needs the special sheers liked used to cut Kevlar®.
Clamps: Small c-clamps, spring type clamps, or homemade clamps.
These are the basic tools. Additional types of tool will depend on builder desires.
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
Mirrored Copies
• 2 copies of each panel are required. They are to be MIRRORED COPIES of each
other. 1 for the left half of the hull and one for the right half.
JEM Watercraft - Free Canoe Plans
• Establish which side of the panels will face the outside or inside of the boat. Mark
them so you don’t get confused. This is especially important if using wooden butt
blocks. You do NOT want the wooden butt blocks on the outside of the hull!
JEM Watercraft - Free Canoe Plans (above image is for reference only)
• After completing the 1st, panel splice, you may use it as an alignment tool for the
second copy. This way, you won’t have to do the alignment with the string again.
JEM Watercraft - Free Canoe Plans
• While keeping track of which side of the panel is the inside and which is the outside,
flip the panel over.
o Tip: Once all panels are assembled, inspect and sand where needed. It is
easy to think “Oh well, I’ll just sand that later”. But trust us… it is easier to do
JEM Watercraft - Free Canoe Plans
clean up and fairing (a term we’ll discuss later) as you go along rather than
waiting to do all the clean up after the panels are assembled.
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
The panels can be finished with a wooden butt block or fiberglass splice.
JEM Watercraft - Free Canoe Plans
• Wooden butt blocks will help add stiffness to the hull but can make applying fiberglass
more difficult. They do not look as “clean” as fiberglass splices.
• Fiberglass splices make applying fiberglass easy but are slightly more time consuming
to install. They do not offer the stiffness of wooden butt blocks.
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
Fiberglass Splices
JEM Watercraft - Free Canoe Plans
• Follow the same procedure to align and join the panels.
• Fill in any voids in the seams, sand smooth any excess cured material.
• Measure and cut a fiberglass patch that is a total of 10” (25.4 cm). The patch will be
centered over the panel seam. You may wish to cut the patch a little over sized to
JEM Watercraft - Free Canoe Plans
allow for the woven fiberglass strands to unravel on the edges.
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These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
7. Hull Stitching
• Plastic zip (cable) ties or copper wire for stitching.
• Start with the Mid Panels. Lay the Mid Panels on top of each other so you are drilling
JEM Watercraft - Free Canoe Plans
through both panels at once.
• Thread the stitches through just the ends of the Mid Panel and spread open. Do not
JEM Watercraft - Free Canoe Plans
make the stitches too tight. For now, leave them a little loose.
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
9. Bow/stern Alignment.
JEM Watercraft - Free Canoe Plans
• Depending on how well/consistent you assembled the panels, the bow ends may
need some trimming for a straight and perpendicular seam.
• We recommend you do not do this until all hull panels are stitched together.
• View the bows from a distance. Trim the ends of the panels as needed.
• A slight gap up to ½” (12 mm) ok on the bow/stern for easier fiberglass application.
JEM Watercraft - Free Canoe Plans
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These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
• Mix the resin. After the resin is thoroughly mixed, add wood flour until it is the
consistency of peanut butter. This is known as “Filleting Material”.
•
JEM Watercraft - Free Canoe Plans
Place a small amount of filleting material in the seam gaps between your stitches. You
can apply material right over the corner of the frames since they were masked off earlier.
• You can apply the filleting material many different ways. Check out our forums and ask
what other builders prefer to use and why.
• Fill as much of the gap as possible between the stitches. DO NOT get the material on
JEM Watercraft
• Note: Work neatly and-clean
Free
the stitches. Let fully cure.
Canoe
up excess material and Plans
drips while
still uncured. It will be much easier to take the time to do this now
rather than sanding it off later. Please take this advice! You’ll be
glad you did.
JEM Watercraft - Free Canoe Plans
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These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
• Allow to fully cure. When cured, remove the stitches and fill in the remaining gaps from
JEM Watercraft - Free Canoe Plans
the hull exterior. The Frames might fall out of place with the stitches removed. This is
acceptable but don’t go out of your way to remove them.
• Note: If you have to flip the hull to get some of the stitches out, do so with a helper and
proceed very carefully.
Interior Exterior
JEM Watercraft - Free Canoe Plans
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
• Before detailing how to apply fiberglass cloth, we must look ahead a couple steps. This
hull will require the installation of gunwales (also known as gunnels, inwales, outwales,
rubrails, etc).
JEM Watercraft - Free Canoe Plans
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
Back to fiberglassing…
JEM
Note:
Watercraft - Free Canoe Plans
For filleting and fiberglassing seams, there is a technique known as “wet-on-wet”.
This consists of applying fiberglass to a seam fillet that has not completely cured. It allows
you to shape the fillet as the glass is being laid over it. This helps reduce the chance of air
bubbles getting into your seams. To do this, simply apply the fillet, allow the material to cure
JEM Watercraft - Free Canoe Plans
until it reaches a chewed bubblegum like consistency, and then apply the fiberglass.
This technique is best used when working with the seams on the interior hull. It is not very
effective on seams of the hull exterior. However, if you have to fill in a small void on the hull
exterior, you can apply fiberglass over it before it is fully cured.
JEM Watercraft - Free Canoe Plans
• When complete, wipe down the entire hull exterior with a lint free cloth dampened (but
not dripping) with water to remove dust. Allow to fully dry.
• Scrub hull seams with acetone if amine blush is a concern.
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These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
• Mix the resin and apply from the center of the cloth area to the outer edges. The resin
JEM Watercraft - Free Canoe Plans
•
can be spread with a squeegee, brush, or a foam paint roller (our preferred method).
Be sure work out any small air bubbles that get trapped under the cloth. Usually these
can be removed by rolling over the cloth back and forth a few times with a little extra
pressure. For stubborn air pocket, use a gloved finger to “squish out” the air pocket.
• After cure, inspect your work looking for areas that did not wet out and are dry. Small
JEM Watercraft - Free Canoe Plans
•
spots are acceptable. Sand these out and remove any dry cloth.
Any spots that did not wet out larger than the width of your thumb will need a fiberglass
patch applied. If you’re not sure if a small patch is required, error on the side of caution.
• Apply 2 more thin coats of epoxy.
• Be mindful of amine blush issues. If you apply additional coats of resin with 48 hours of
JEM Watercraft - Free Canoe Plans
the previous coats, you should have no amine blush issues. The quality of epoxy used
will dictate these results.
• To ensure against amine blush, you may scrub the surface lightly with acetone. Follow
all required safety guidelines when working with solvents.
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
16. BOM Option #1: Apply Fiberglass Tape to the Hull Chines (Seams)
JEM Watercraft - Free Canoe Plans
• A “chine” is a name for the hard angle created when to hull panels meet.
• Select one chine to work with and lay the fiberglass tape over it. The fiberglass tape
weave is stretchable so work it with your hands to get it to conform to the shape of the
hull. You can hold it in place with small pieces of masking tape just along the edges.
• You can lay overlapping sections of tape but if you’re a new builder, we recommend
JEM Watercraft - Free Canoe Plans
working with one chine at a time, letting cure, then working with another chines.
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
o Reminder: The general rule is that each seam must have smooth, tangent
JEM Watercraft - Free Canoe Plans
radius equal to the thickest panel of wood. Review the section about working
“wet-on-wet”.
Interior Exterior
• Note: The bow/stern ends will be the most difficult because of the sharp angle the
panels meet at. Extra filleting material will need to be push into that seam. Keep adding
material until you are able to smooth it out with the tip of a plastic spoon (or which ever
JEM Watercraft - Free Canoe Plans
•
tool you choose to use).
These sections are easiest to use the wet-on-wet method.
o Do a dry run to size up your cloth and decide where slits may be needed. Size
the cloth so you cover the entire bow seam plus about 12” (30 cm) of each side
of the hull panels.
JEM Watercraft - Free Canoe Plans
o Apply filleting material to the seams
o With a foam roller, roll on a thin layer of epoxy where the cloth will go.
o Place the cloth and work it into the bow seam with your gloved fingers getting all
the air out.
o Roll the epoxy onto the cloth ensuring a complete wet out and that all air pockets
• Repeat the process for the remaining hull interior. It’s best do not rush into this. Do
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These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
Note: Unless you’re working with a helper, consider working in smaller sections or be
JEM Watercraft - Free Canoe Plans
prepared to work very quickly. This step is easy to write but requires a lot of effort. Be sure
to prep your area and have all tools in place and ready to go. You do not want to have to be
searching for tools while the resin is curing.
• Mix the resin and apply from the center of the cloth area to the outer edges. The resin
JEM Watercraft - Free Canoe Plans
can be spread with a squeegee, brush, or (our preferred method) a foam paint roller.
Note: Resin cures with an “exothermic” reaction. Meaning it gives off heat
as it cures and will cure faster with additional heat. If using a foam roller,
some resin will remain in the foam toward the middle of the roller. As it
JEM Watercraft - Free Canoe Plans
cures, it will give off heat and cause any resin near it to cure faster and
could cause problems wetting out your cloth. To avoid this becoming an
issue, change the foam roller about every 10 minutes or if the roller starts
feeling very warm to the touch.
JEM Watercraft - Free Canoe Plans
• Inspect your work looking for areas that did not wet out and are dry. Small spots are
acceptable. Sand these out and remove any dry cloth
• Anything larger than the width of your thumb will need a fiberglass patch applied. If
you’re not sure if a small patch is required, error on the side of caution.
JEM Watercraft - Free Canoe Plans
• Apply a second coat of epoxy. Be mindful of amine blush issues.
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
• An alternate method of attaching the frames and bulkheads can be done by gluing
JEM Watercraft - Free Canoe Plans
•
sections of woodworking trim, usually sold in 8’ lengths. Minimum width of 3/8” [9mm].
Square strips or ¼-round will work nicely.
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
• Wrap the dam in clear packaging tape or wax paper and hold in place with clear
JEM Watercraft - Free Canoe Plans
packaging tape.
• Tilt the hull so the opposite end from the one you’re working on is raised. This will
ensure the top of the end pour is angled down so any moisture that may collect will
drain.
JEM Watercraft - Free Canoe Plans
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
• Glue the deck into place. We also recommend driving 2-3 small stainless steel wood
JEM Watercraft - Free Canoe Plans
screws from the hull exterior into the deck. Be sure to drill a pilot hole first to prevent
splitting the wood. Drive the head of the screws so they are beneath the surface of the
hull plywood.
JEM Watercraft - Free Canoe Plans (above image is for reference only)
The decks can be shaped for more decorative looks. Just be sure to leave the minimum
dimensions.
JEM Watercraft - Free Canoe Plans
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
Install Gunwales
JEM Watercraft - Free Canoe Plans
• Gunwales are require to provide stiffness and structural strength to the hull.
• The gunwales must be at least a total of 1” (2.5 cm) thick and 1.5” (3.8 cm) tall. We
recommend an inwale, installed on the sheer line of the hull interior, and an outwale,
installed on the sheer line of the hull exterior.
•
JEM Watercraft - Free Canoe Plans
Gunwales can be made of solid lumber or in strips/layers building up to the minimum
thickness.
• Glue the gunwale pieces directly to the sheer line. Hold in place while glue is
curing with temporary screws or clamps. If constructing the gunwales from strips
of plywood, install one layer at a time. Let one layer fully cure before installing the
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
• Additional layers of fiberglass may be applied or a series of flat ribs may be installed in
the midship area.
JEM Watercraft - Free Canoe Plans
JEM Watercraft - Free Canoe Plans (above image is for reference only)
• Glue the ribs in place. For added stiffness, bevel the edges of the ribs and apply a layer
of fiberglass over each rib.
JEM Watercraft - Free Canoe Plans
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These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
DK-Touring Build Instructions
Rev 00 – 02/10/07
JEM Watercraft
• Be sure to check out our “Tips and Tricks” section for ideas like applying graphite to the
JEM Watercraft - Free Canoe Plans
hull bottom to make it more abrasion resistant.
26. Take pictures of your kayak in action and send them to us. This is the most
important step of them all! ;) Don’t forget, you can get a rebate on the cost of the
plans by sending pictures. Contact us for details.
JEM Watercraft - Free Canoe Plans
27. ALWAYS use good judgment and wear your PFD.
28. Did we mention to ALWAYS use good judgment and wear your PFD?
Now that you’ve built a set of our free plans and can see how easy and enjoyable we
make the process, please consider us for any future building projects you may have.
JEM Watercraft - Free Canoe Plans
We’ve put a lot of work into providing these plans for free. If you can, please support us
by purchasing your building materials from one of our partners and mention you’re a
JEM Watercraft customer.
These instructions and its concepts may not be used, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.