FAQs » Shearwater Kayaks
Are there any significant differences between building the Shearwaters and the Chesapeakes?
The sequence for the standard Shearwater is thus: Wire the hull up like any other CLC boat, install fillets, etc. Wire together the deck (with a few temporary forms providing the deck camber), apply "tack welds" to the deck, and wire it onto the hull. Take the deck back off to finish the fillets and fiberglass on the deck. Like most of the hull, the deck is fiberglassed on both sides; there are about four layers of 'glass right behind the cockpit. At a last you wire the deck on for good and apply fillets to the hull-to-deck joint.
The Shearwater Hybrid process is different: there are temporary forms upon which the stripped deck is assembled, and the hull has the usual CLC sheerclamps to which the strip deck is ultimately fastened once the forms are removed. Definitely takes more time to build, but a fraction of the time of an all-strip hull.