Hi Steve,

A S&G kayak is essentially a 3 dimensional puzzle. If the pieces are not going together properly you will likely have to cut new ones or change the design.

When you design a S&G all the panels should fit together to create the desired shape without being forced. The only bracing should be a cross piece or two to set the beam. This is easily said but not so easily done without a program that will develop flat panels from your design. There are a number of programs ranging from very expensive professional ones to freeware you can download from the web.

Last summer I designed a S&G kayak specifically for a small novice paddler - my 13 year old son. It took a lot of time, trial and error but in the end I got what I wanted. I designed as I built. This is not the easiest way to go about it.

In simplistic terms, I developed the kayak's shape by positioning four 12 inch by 16 foot panels in the correct locations and fitting them together. Very subtle adjustments to the shape causes a large changes at the far end of the panel.

After attaching a shear [3/4"x 1" x 16' spruce] to the side panels, I cut the bow and stern to the shape I wanted and stitched them together. A spacer was put at amidships to give a starting beam. A couple more spacers were added at the shear and the whole works was suspended with two ropes at a convenient height. An other dozen or so spacers were installed at the shear and the chime to create the shape I wanted for the hull.

I then made a rectangular bottom with the rocker and a shallow "V" by fitting/stitching two 12"x 16' panels together.

The stitched bottom was positioned [propped and shimmed] and the rest of the hull was lowered into position so that the interface of shapes could be transferred to the side panels. The shaping of the side panels took a bit of fooling around and several trial cuttings. With the sides cut to profile and the hull shape being determined by the spacers, it was easy to position the bottom, trace the contour and cut it to match.

It was pretty routine after that, drill, stitch, fillet, bulkheads, deckbeams, deck and finishing.

It was an interesting project. Gave me an appreciation what actually goes into a kayak design.

Would I do it again? Not likely, I had a special requirement. It is more practical [time/money] to buy a proven set of plans from a professional - at $50 to $100 it is a bargain.

I would not discourage anybody from designing their own kayak - I had a lot of fun. I just hope you like 3D puzzles ;-)

Hope this helps.

Hank