Ze SE Ud ~ FYIVLAWNNWIWOOWELNI WAL oN aLS€ Adv Ofo0ossoseezze Weds - seoseezz’ SOU — 092 LEL 3 ep leydeo ne TuYs ~ (eouUes4) SIOIVA OBPES ASVOAd SPIANOV.P Wed SenbqneN sIoUsieN op UoRalsia ep 9 UoREOUGE, oP pi9!20S 49BULNs JMO} Jebunns Jedd, 4eq yoap do} wars piwoqiooy Was 46 aremung us Aiquiesse Was Aiquiesse MOR, SINVYs NSGOOM i NOILIGSdxX3 02S Il divy GNVYS Clivanir WN?Bateaux pliants @ NAW I IRA) congus pour l'extréme, faits pour vous GRAND RAID 11590 EXPEDITION Wooden frame ASSEMBLY INSTRUCTIONS Allow plenty of time for your first assembly. Use patience, no force ! Your kayak has already been assembled in ‘our factory for a final check before shipping, Read the instructions carefully and review them again if you find yourself using excessive force. WHEN UNPACKING YOUR KAYAK FOR THE FIRST TIME, YOU MAY WANT TO CHECK AND MEMORIZE HOW YOUR KAYAK HAS BEEN PACKED IN ITS CARRY BAGS in order to reproduce the same result, This facilitates rapid packing and aids in speed of deployment as well as ensuring that when disassembling in a hurry that you reproduce an easily portable load. Properly repacked you will not have to force ‘the zips on the carry bags. (Aliso see attached packing pictures). Find a level space free of sharp gravel. ‘Then take a few moments to familiarize yourself with the various frame components. Bow components have 2 red marks and stern components one blue mark. Use the diagram to locate specific parts. Your kayak consists of the following components: 2 carry bags, one for the frame, the other for the skin, 1 ‘wooden frame,1 skin, 2 inflatable seats and their foamed backrest. The wooden frame consists of 15 separate pieces or pre-assembled sets to put together: one bow sub-assembly, one rib*3, one bow keel extension, one stern sub-assembly, one rib®7, one stern keel extension, one bow floorboard piece, one stem floorboard piece, one rib 1n°4, one rib n°5, one rib n°, one laminated wooden cockpit coaming made of one front curved piece, one left straight pigce, one right straight piece and one rear curved piece. Rib references are from bow to stern (front to reat), 1109. ASSEMBLE YOUR KAYAK STEP BY STEP. THE ORDER IS IMPORTANT. Always work front to rear. 1- ERECT THE BOW SUB-ASSEMBLY ‘Tum ribs n°1 and n°2 perpendicular to the kee! (a1). The bevelled notches should face the bow. Snap the attached hinged gunwales into place on the notches. Attach the rubber straps on the gunwales on the screw Iheads on rib n°1 and n°2. 2. CONNECT THE BOW KEEL EXTENSION TO THE BOW SUB-ASSEMBLY Align the two keels first with the two red markings facing each other. Keep an angle to insert one section into the fitting on the other (a2) and to allow the short pin on one keel to get into the corresponding hole on the fitting on the other keel. Notice that the bow keel extension has a lever arm on it. 3- CONNECT RIB N°3 TO THE BOW SUBASSEMBLY AND TO THE BOW KEEL Insert the rotating deck bar extension on rib n°3 (a3) (two red marks) into the fitting on the top of the deck bar ‘on the bow frame. Pin it (a4). Then insert the screw head on the bow keel extension into the stainless steel fitting on rib n°3 base (a8). Lock the fitting. Pivot the hinged gunwales and stringers around their hinges (a6- 1, a6-2, 46-3). Start on one side. Do the same on the other. Take one gunwale in one hand and the lower ‘stringer in the other (a62). The upper stringer (between gunwale and lower stringer) will follow the two others in the same sequence. Never try to pivot the gunwales and the stringers before the gunwales have been snapped and secured on notches on rib n°1 and 2. Snap the gunwales into place on rib n°3 notches. Fasten the rubber straps on the gunwales to the screw heads on rib n°3. Double check that the gunwales are even on both sides of ribn°l, 2, 3 notches. The bow assembly is now ready to be inserted into the bow end of the hull, 4- REPEAT THE ABOVE PROCEDURE WITH THE STERN COMPONENTS. Stem subassembly and stem keel extension are recognizable by one blue mark. This is a mirror image of the bow assembly procedure. Double check that the gunwales are even on both sides of rib n°6, 7 and 8 notches. ‘The stern assembly is now ready to be inserted into the stem end of the hull.5- FULLY INSERT THE BOW FRAME INTO THE SKIN OF THE FRONT HULL (a7-a8) It is important to make sure that the front frame and skin are “in line: they must be centred (a9) and it must be ensured that where the hull material joins with the deck material under the seam, it is located over the ‘gunwales, equally on both port and starboard sides for the full length of the hull. 6- REPEAT THE ABOVE PROCEDURE WITH THE STERN FRAME ‘The plastic rudder cable housings should rest over ribs n°7, 8 and 9 tops. Make certain they are not pinched between frame and hull. 7- CONNECT KEEL EXTENSIONS, When bow and stern frames have been inserted into the skin, fit the aft end of the stern keel into the brass pin joining the lever arms on the bow keel. Pressure the lever arms down (a10) until the bow and stem keels mesh. Turn the stainless steel plate perpendicular to the keel to secure the lever arms. 8 CONNECT THE GUNWALES AND STRINGERS Start with the gunwales on one side (a11). Then do the same on the other side Continue with the upper stringers. Finish with the lower stringers, They have a “spring fit”. Pull and bend the fore and aft gunwales in ‘order to insert the front gunwale into the stainless stee! joint on the rear gunwale, Repeat with the stringers. Insert the screw heads on top of ribs n°2 and 6 through the corresponding eyelets on the skin (a2) 9- INSTALL THE FLOORBOARDS Begin with the bow floorboard with the two red marks, The two red marks toward rib n°3. Slide the two floorboard ends beneath rib n°3 base. Repeat with the ster floorboard (one blue mark) on rib n°7. To connect the bow and stem floorboard pieces, first mate their ends together in the middle of the cockpit area and, when they contact each other (a13), press them down and make sure there is contact along the keel 10- CONNECT RIBS n° 4,5 AND 6 Rib n°4 has two sed signs on its base, Rib n°S has an additional removable support on it for the front seat backrest (fastened with two wing muts) and is the central rib in the cockpit. Rib n°6 has one blue sign on its ‘base and two small holes at its top ends to screw the removable front backrest support to when necessary (Golo operation seat postion). Connect rib n°5 first. Note that the front seat backrest support must be located on the front side of rib n°S and not on its rear ! Insert the screw head on the central kee! into the stainless steel fitting on the rib base, Lock the fitting (416), Snap the gunwales into place on the notches on rb n°5. Inset the screw heads at rib n° top ends through the corresponding eyelets on the skin around the cockpit opening (a1). Repeat the above procedure with rb n°. Rib n°6 is connected in the same way as rib n°4 Double check that the gunwales are stil located in the rib notches on both sides of the frame. ‘Connect the rubber straps that hold the gunwales to the stringers to the screw heads, which are located on the keel 11- ASSEMBLE THE COCKPIT COAMING (a17) Connect the curved fore and aft components together using the straight pieces, Ensure that the groove in the ‘wooden coaming runs continuously around this sub-assembly and is facing upward, ‘When fully assembled, put the whole set on the kayak (a8). 12- CONNECT THE COCKPIT COAMING TO THE KAYAK Insert the screw head on top of rib n°3 (ai8) into the fitting beneath the cockpit coaming front, Then repeat at the rear of the cockpit coaming with the screw head of rib n°7 on top at the back, Then, follow on, ‘on both sides, with screw heads on ribs n°4, 5 and 6 on top. Pull up the black binding material on the skin on. the intemal side of the coaming and press it into the coaming groove. Proceed from rear to front on each side, Pinching the binding material with two fingers on one hand, press it down into the groove with the palm of the other hand (a19). Check again that gunwales fit the notches on ribs n° 4, 5 and 6, 13- CONNECT THE INFLATABLE SEATS AND FOAMED BACKRESTS (On the rear seat, pass the rear shortest straps, with their quick release buckles at their ends, under the two ‘wooden struts behind the seat’s wooden platform and around rib n°7 base. Then connect the quick release ‘buckles (a20). Pass the front straps, with their quick release buckles at their ends, over rib n°6 base then down around the wooden strut behind the solo-operation seat’s wooden platform and connect the quick release buckles and adjust the length and tension (a22). Pass the long strap located on the backrest rear top ‘over rib n°7 top on the right side in relation to the screw head (220), then down around n°7 base on the left side in elation to the keel, then beneath the inflatable seat toward the front of the kayaik, then over rib 1°6 ‘base, Pass the strap end under the wooden strut in front of rib n°6 (a22). Velcro the strap end. Connect the two straps on each side on the back rest to the projecting quick release buckles on each side on the cockpitcoaming area (222). Inflate the seat as necessary to get the comfort you need. Tighten all straps in order to ccurve and bend the backrest to get optimum comfort. On the front seal, pass the rear shortest straps, with their quick release buckles at their ends, under the ‘wooden strut behind the front seat’s wooden platform, under rib n° base and under the wooden plate behind rib n°5 before connecting the quick release buckles (a21). Pass the front straps, with the quick release ‘buckles at their ends, over rib n°4 base then down around the wooden strat in front of rib n° and connect the ‘quick release buckles (a2). Pass the long strap located on the backrest rear top through the slot in the middle ‘of the removable support for the front seat backrest, then down around n°5 base on the left side in relation to the keel, then beneath the inflatable seat toward the front of the kayak, then over rib n°4 base (421). Pass the strap end under the wooden strut in front of rib n°4. Velcro the strap end (a2). 14 INFLATE AIR SPONSONS Inflate air sponson longitudinal buoyancy tubes to the maximum amount of mouth pressure. If necessary use 8 small inflator. Do not use air compressor. Beware ofthe over-inflation of air sponsons which should result of high temperatures under the sunshine. Adjust the pressure accordingly. 15- INSTALL THE RUDDER SET (have a look first on the rudder kit assembly instructions if you originally purchased your GRAND RAID 540 Expedition Wood without any rudder. Put the rudder on the rudder bracket on the kayak ster, Pin it. Keep the two ropes that control the rotation of the rudder blade into the pin eye. Clear the two ropes and connect the loop they make to the hook at the end of the black small shock cord on the skin on the right side of the cockpit. Adjust the tension with the stopper. Unscrew the left rope on the rudder yoke, pull the removable ring off the yoke. Insert the yoke through the rudder head. Put the removable ring back on the yoke and firmly screw the left rudder rope back on to the yoke (a23). Inthe cockpit, connect the ropes on the pedals to the rudder wires and to the shock cords on rib 'n°3, With the stoppers adjust the location of the two pedals in relation to the rear seat (25). When down in the ‘water the rudder blade must be maintained between the two rudder lips. Therefore pull on the corresponding. rope and, when taut, insert it into the stop cleat on the right side of the seat on the skin (26). Before bbeaching, with one finger, pull the rope off the stop cleat. The rotation of the rudder blade must be operated ‘with the two ropes from the two plastic blocks, one pushed, the other pulled. 16- INSTALL THE SPRAYDECK ON THE COCKPIT COAMING Put the front end of the spraydeck around the front end of the cockpit coaming. Pull the spraydeck backwards and push the elasticated end of the spraydeck under the cockpit coaming end. Fasten the straight sides with the velero straps SOLO OPERATION SEAT POSITION Lis recommended to move the rear seat forward in the cockpit to keep the kayak balanced. Unscrew the backrest support on rib n°S and screw it back on rib n°6, Take the rear seat and backrest and fasten it back in relation to sib n°, Adjust the rudder pedals accordingly. Use a solo operation spraydeck if necessary CARING FOR YOUR KAYAK Under sunshine, deflate the air sponsons to avoid over-pressure Always protect your kayak from sun and rain when not in use, When folding for storage, make sure all components are clean and dried before packing. Periodically remove the frame from hull and clean out sand and grits from hull and frame, Maintain varnish as necessary. This will require a soft abrasion before varnishing. Rinse your kayak with fresh water after exposure to salt. Dry your kayak keep it assembled, tumed down, sponsons deflated. Remove the salt that can be accumulated on the frame and clean it with a siliconed cotton waste Deflate air sponsons when not in use, When necessary patch with pve or pu glue on deck and sides. But neoprene glue is necessary on bottom. A soft abrasion is necessary on the two faces to stick, prior to patching with neoprene glue. ‘A mild detergent (liquid dish soap) may be used to clean the hull, Never use solvent. Lubricate fittings with silicone or teflon spray. Avoid humidity for winter storage . Don’t drag your kayak on the ground and avoid shallow water.GRAND RAID Il 520 EXPEDITION WOODEN FRAME ASSEMBLY INSTRUCTIONS 47GRAND RAID II 520 EXPEDITION WOODEN FRAME ASSEMBLY INSTRUCTIONS re Aas > aié aly ai8 aisGRAND RAID II 520 EXPEDITION WOODEN FRAME FOLDING AND PACKING THE SKIN iD 14GRAND RAID Il 520 EXPEDITION WOODEN FRAME PACKING THE FRAME Wa