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Construction Options

Plastic Boards and Kayaks

Our plastic kayaks and paddleboards are made in several different ways, depending on the general intended use of each model and style. All of the plastic boats and boards are rotomolded using the best materials available on the market. We offer two basic styles: Light weight construction, where the user knows that they're not going to be constantly smashing the boat or board into rocks, and the strong construction, where continuous and frequent rock contact is part of its intended use.

Everything is give and take - a balancing act between weight, stiffness and impact resistance. Knowing how and where you're going to use your board or boat allows you to select the best construction method.There is no perfect way for everyone, everywhere and every style, so you pick the method that works best for you.

The rule of thumb is that our Orange kayaks and boards are the heavier and stronger of the two options: A single thick layer of high density polyethelyne (HDPE) that offers both scratch and impact resistance.

The Impact resistant kayaks are built using a single layer of HDPE, distributed carefully according to where the kayaks needs to be stronger or stiffer, and thinned out where its not needed to reduce weight. The majority of the kayaks overall stiffness comes from the internal bracing skeleton. The District 11, Gonzo, Main Squeeze, Jailbait are all made like this in either Yellow "light weight" or Orange "heavy duty" versions.

 

The lightweight Paddleboards like the lightweight Firestorm are made using the Dual Core construction: a medium thickness HDPE outer skin that offers both impact and scuff resistance, and then a thick lightweight internal foam core for maximum stiffness. This construction method allows to significantly reduce weight and make a completely rigid board where abuse from rocks is going to be minimal (It will take impact, but it can't be pounded like a single skin HDPE).

 

Some lightweight kayaks and the Firestorm are made using this Tri-Beam (like an I-beam) construction method where both impact and stiffness are needed. While not quite as stiff as the Dual Core, for the weight it's significantly stiffer than a single layer of HDPE. For boats like the District 11, this is used and suggested for paddlers who will be using the kayaks in whitewater, where stiffness and light weight trumps all-out impact resistance; rivers that are mostly water but the occasional rock impact is to be expected.

 

Epoxy Boards and Kayaks

We build all our epoxy composite boards and kayaks (Buzz Kill) by CNC machining low density EPS foam cores, which are then hand finished to get the details exactly right. The boards are then vacuum bagged using only the most advanced composites on the market today. Each board has a slight variation of the overall construction method, depending on its final intended use - whether top end strength is required, dent proof rigidity, or ultra light weight. The X, Jibber and Buzz Kill for example use combinations of our "2 over 1" kevlar/carbon material, in conjunction with high density PVC foam skins and kevlar. Conversely, the Session and Sprint use only the Kevlar/carbon material with carbon reinforcing where ultra light weight is critical. Finally, boards like the Groovy and Odyssey use combinations of PVC high density foam and Kevlar/Carbon for a great middle ground of strength to weight ratio. This is what sets our composite boards apart from the mass out there.