Carbon composite Canoe build help and advice please

Hi Folks.

After recently fixing up a few canoes, I became interested in building composite canoe. The goal is to use an existing ~16’ tandem canoe as a male plug (not to be destroyed), layer s-glass, carbon fiber, the s-glass, then either carbon over foam for trim out or wood (tbd).

Here are some basic points:

Goals:

1. Generally match the profile of the existing hull with minor tweaks such as lowing the sheer line and tightening up the beam.

2. Achieve an ultralight canoe with more emphasis on weight reduction than longevity or durability (…or comfort and stability). Flat water only. Aiming for 30-40lbs finished weight.

3. Determine if this is a project style I want to repeat with further improvements/adjustments in the future.

Notes:

1. I am aiming for a release agent, either chemical/liquid/wax, film, or peel ply over the existing boat; hand layup of all layers, squeegee, then filling and finish.

2. I recognize that I may have to split the ends to remove the new hull from the existing.

3. The existing hull has a built in wide keel that I hoping with add some rigidity to make up for a foam football floor or ribs.

4. This is not a ‘forever’ canoe…this is a can it float, is it rigid enough for flat water, how light did I get it, is it worth the time to repeat with bagging or bagging and infusion, and did I enjoy the process.

5. I don’t mind being a bit reckless with design and build, if it doesn’t pan out, I will not consider the few hundred bucks the cost of exploring the process.—we all spend a bit on hobbies.

6. I’ve contacted the original manufacturer and they couldn’t give a hot damn about what I am planning on trying out.

More on the plug:

1. Sub 16’ prospector (ish), glass, molded keel, very old. 42 lb hull, total 53lb with new pine and ash trim out.

2. It was (probably) 35”ish max width and 34 at the yoke. I slimmed her up a bit when I replaced gunnels/seats/yoke. I have enjoy the change, makes it more fun for leaning over for tooling around on glassy water.

3. Approximately 60 square feet of hull surface area, but the new hull will be lose between 1 and 1.5” at sheer line, I have not calculated new projected sqft.

4. I will likely pop off the gunnels and fatted her out to 36 at the yoke to assist in performing as a plug and give me a chance to achieve a bit of pre-tension in the new hull (maybe a really bad idea…let me know).

Layup/construction:

1. Peel ply

2. 4oz S-glass

3. 5.8oz 3k carbon twill

4. 4oz S-glass

5. Kevlar stern and bow protection

6. Either glassed wood or just wood, or carbon over closed cell foam gunnels (only inners, no outers).

7. Seats may be webbed wood frame, or carbon of similar design, or just angled kneeling thwarts fore and aft like I have used in asymmetrical tandem canoes for solo. Similar construction for the yoke, deep dish yokes have never felt that great to me and I am not a fan of pads.

I have a few questions and would love some advice on the following:

1. Would the above result in anything close to a useable boat? Or just an expensive version of a paper boat…

2. Will the built in keel/molded keel help enough to prevent oil-canning?

a. Should I build according to the above, then test float and address issues with either another layer or two of carbon, or give in and add the foam core or other supports before the interior glass?

3. I have found some folks on this forum and others that have undertaken similar projects but not too many that have done it exactly this way, and if anyone did…I guess they didn’t post about it.

4. My very optimistic math on fabrics and resin says that with the layup described above, it I might be able to get close to a 25lb hull if I know what I’m doing (which I do not, but I am handy) and I think I can figure out a 6-10lb trim out which would get me into my desired weight class. Please let me know if think this is fantasy!

I am new to the forum, but am keen to hear from anyone with experience, especially if you’ve done this and want to ‘try’ to set me straight before I order the materials.


Thanks!

 

Why?

What is the objective? ( S.O.R. )

Do you have any drawings or just complicated text?

 

“SOR” means “statement of reasonings”? If yes, please see the original post. I called them goals—confusing right? the tldr objective is make a boat from a boat with different materials, for enjoyment of the process and fun. Woot woot.

No drawings in hand or available—but I’ve got the male plug. If you’ve made a composite canoe from an existing non-sacrificial male plug, feel free to contribute if that is your SOR.

 

Mixing glass and carbon doesn't help you, pick one or the other and build it with that one. Adding Kevlar in wear points can help, but it needs to be positioned in the laminate correctly for it to achieve your desired goals.

What is the peel ply for in that location?

 

Pictures of the plug?