A composite endcap is a custom-fitting, repairable, protective cover for the stern of a slalom boat.
By using this type of endcap, you can ensure that the tip of your stern remains exactly as it was when it came out of the factory mould; that is to say, it will remain wholly undamaged, thus preserving its structural and design integrity. Let the endcap take the wear-and-tear of training instead of your new slalom boat.
Follow the step by step instructions and photos to build your custom endcap.
1. Before the stern gets damaged, wrap 4-6” of the end tightly in plastic cling wrap. SEE PHOTO #1
2. Cut pieces of Kevlar, Dinal, Carbon-Kevlar, or Carbon to fit the shape of the seams and hull-side of the stern. Prepare enough to make at least 3 layers at the tip. Fewer layers are needed in other areas. SEE PHOTO #2
2b. Cut glass for two top layers if Kevlar or Dinal is used. Glass and Carbon can be sanded/scraped without fraying and absorbing water during wear and tear.
3. Mix 15-20 mL of epoxy resin (West Systems works well). SEE PHOTO #3
4. Lay pieces of composite fiber onto the stern once saturated with resin. Top layers can be saturated with the excess resin from bottom layers and therefore should not be oversaturated themselves. Remember that glass and/or carbon layers go on top of Kevlar and Dinal. SEE PHOTO #4
5. Pull cling wrap tightly over the stern and squeeze excess resin and bubbles out with a wet piece of mini-cell foam (for those who are not squeamish, spit works best). Be sure not to squeeze fibers out of place or resin beyond the initial layer of plastic. SEE PHOTO #5
6. Once cured (6-10 hours), remove everything from the tip of the stern. Remove any plastic wrap that may have stuck to the stern or endcap.
7. Paint a thin layer of waterproof contact cement around all the inside edges of the composite endcap and on the corresponding spots on the stern. Let the contact cement dry completely (15 minutes) before joining pieces. Caution: If you paint the entire inside of the endcap and tip of the stern with contact cement, it may be difficult the remove for repairs. SEE PHOTO #6
8. Go paddling!
Making A Composite Endcap
to protect your slalom boat
Copyright 2006 © Danny Stock. All Rights Reserved
PHOTO #1
PHOTO #6
PHOTO #5
PHOTO #4
PHOTO #3
PHOTO #2
