Wal-Mart sells sheet vinyl in the fabric department. The industry identifies different thicknesses either by a gauge size (12 gauge would be thicker than 18 gauge) or by an actual thickness, usually expressed in 'mils', or thousandths of an inch. Unfortunately, I don't have a comparison between gauge sizing and real thickness. To make things a bit more difficult, Wal-mart just calls their stuff by descriptive names, 'lightweight' 'heavy-duty', etc. Jo-Ann's products use gauge sizing.

Wal-mart's thickest stuff is what you want. It used to be $3.58 a yard in the Chicago area, but last time I looked it was a bit over $4 in Indianapolis. Price difference could be from increased oil prices, or regional differences.

I've seen two 'heavy-' and 'extra-heavyweight' vinyls on the rack at several Wal-marts. They appear to be exactly the same. I suspect the sales clerks can't tell the difference . Just buy the thickest they have. I think it is 25 to 40 mils thick.

Six yards, or about $25 worth, covers a 15 to 17 foot kayak. Cutoffs and excess make floatbags and gear bags.

Sevylor makes inflatable boats, including kayaks, out of unreinforced vinyl which is this thick, or thinner. These are not their best boats, but they last several years. I had one last two years before squirrels started nibbling on it. Squirrels love the taste of vinyl, apparently. I believe it was made from 20 mil vinyl, and very inexpensive. My second boat is over 15 years old and still fine. That one is a thicker vinyl, 30 or 40 mil I believe.

When vinyl is heated it softens and expands. On an inflatable the tubes get a bit limper on hot days. With a rigid wood frame that is not an issue. most of the skin is in the water, and stays at cool temperature. If the deck warms up in the hot sun, it is no big deal. When the plastic cools it shrinks back to its original size.

To avoid driving staples through the vinyl, pull the material into place and cover it with a thin 1/8 inch or 3mm strip of wood. Staple throught the strip and vinyl.

PGJ