Mega Kayaks :: Construction

Our material choice and build explained.

Our gel coat - a special formula that is sprayed into the mould ( typical weight saving is upto 1kg per deck or hull )
Why we only use epoxy resin:
Epoxy resin has 75% fewer VOCs (Volatile Organic Compounds) contained in the resin itself and two-thirds fewer VOCs are released into the atmosphere than from polyester/vinylester resin. VOCs are a source of air pollution and can be a significant health hazard.
Safer and better for the environment ( No Styrenes released into the atmosphere )
Epoxy Resins have performance advantages over polyester and vinyl esters in these main areas.

Better adhesive qualities.
Superior mechanical properties. (Structurally a post cured epoxy pipe exhibits tensile strength and modulus close to double that of polyester or vinyl ester)..
Improved resistance to fatigue and micro cracking.
Reduced degradation from water ingress.
Inceased resistance to osmosis
Reduced thermal and chemical shrinkage (Cosmetically polyester and vinyl resins typically shrink up to 7% whilst epoxy shrink up to 2%).
( we found a weight saving aprox 1 kg over vinylester resin) .

Using only one type of high spec resin through out the boat makes a better product in every way!
(Intersting data here:https://www.compresdev.co.uk/CRD%20The%20Use%20and%20Application%20of%20Epoxy%20Resin%20vs%20Vinylester%20vs%20Polyester.pdf

Our Material:
No more Carbon Kevlar.
The new methods of making carbon fibre now produce a much more ecologically friendly and super strong product. In the last two years of testind we have not had a single carbon fibre kayak breakage.

Our reasons for dropping Kevlar because
1, The manufacturing process of kevlar involves using concentrated sulfuric acid, needed to keep the water-insoluble polymer in solution during its synthesis ( an environmentally damaging process)
2, it no longer has a performance advantage in kayak manufacture.

Our Foam Core:
Now made from 100% recycled PET plastic ( recycled fizzy drink bottles) .
It out performs any other foam core on the market for strength and weight.
So why not ? We thought it was worth the investment.

Our foam centre pillars and foot blocks: 100% recycled
Now made from recycled mini cell foam. We spent two years working and testing the development of this recycling process. The result is a stronger foam . A gain in performance adding to the stiffness and strength of your kayak.

Our seams:
Newer models: Halo, Edge, Matrix , Banshee, Vamp, Viking and Bandit have an inner seam that is part of the boat (no inner taping) , the deck and hull are bonded together with a special epoxy that closely matches the laminate epoxy making deck and hull become one peice. The join is incredibly strong and the added mechanical strength of the inner seam makes the boats very stiff.
Our outer micro seam is a crystal clear epoxy and bonds our signature black composite seam tape to the gel coat, leaving minimal seam area. This avoids disruputing the way the rails work with the water the way larger standard gelcoat seams do.

Our fin boxes. We found that over time plastic fin boxes or mounts gradually give in to the forces they are subject to and fail leaving for an expensive repair. So, we devised our own special anodised alloy fin box, now in it's second generation it is now shorter , lighter and even stronger than any other fin box on the market.

We vac bag our hulls to give superior strength for less weight.

Construction / Lay up options

Surf Kayaks

Plastic PE

Surf grade plastic (Kahuna, Neutron X, Neutron, Maverick and Xray)

Carbon 1

Epoxy resin deck and hull
Deck is: Lightweight sprayed gel coat on E Glass
Hull is: Lightweight sprayed gel coat on E-Glass with 100% recycled PET foam core and an inner layer of Carbon .
Hull is now vac bagged !

Aproximate boat weight 12kg

Super light Carbon +

Epoxy resin deck and hull
Deck is: Lightweight sprayed gel coat on E Glass x 3, 1 x carbon
Hull is: Lightweight sprayed gel coat on E Glass x 2, Carbon x1, with 100% Polyester core ( inner layers Carbon).

Aproximate boat weight 10kg

X-tech Carbon +

Epoxy resin deck and hull
Deck is: Lightweight sprayed gel coat on E Glass x 2, Carbon Kevlar x1 Carbon x1
Hull is Vac bagged Carbon x2, E-Glass x1 with 100% recycled PET foam core ( inner layers Carbon ).

Hull can now be coloured or bare carbon (No cost option)

Aproximate boat weight 8-9kg

Carbolite Pro

Epoxy resin deck and hull
Deck is: Lightweight sprayed gel coat on
Vac bagged Carbon or Carbon Kevlar x2 with a very special core.
Hull is Vac bagged Carbon x3 with 100% recycled PET foam core ( inner layers Carbon ).

Hull can now be coloured or bare carbon (No cost option)

Aproximate boat weight 7-8kg

Green spec

Green epoxy resin made from 70% plant extract.

The deck is: layers of Biotex Flax woven fabrics are reinforcement textiles based on natural flax fibre and designed for fibre-reinforced polymer composite applications. As a premium natural fibre, flax offers improved mechanical properties over alternatives such as jute, resulting in higher strength-to-weight ratio and therefore stronger, lighter laminates.
The Hull is Biotex flax and 100% recycled PET foam core >

No stone left unturned in the pursuit of making the greenest kayak out there!

Elite
Featherlite spec

Especially for the weight weenies out there. The closest thing to an F1 spec we can think of!
This is a full epoxy vac bagged oven cured special build!

No gel on deck or hull , foam core deck as well as hull (lighter , stiffer , stronger) , custom lay up to suit each individual paddlers requirements .

Materials used , Carbon, Carbon and Carbon Dyneema.
Outer seam removed putting the boat back to its most natural form .
Rolled and intergrated cockpit rim with special thigh braces.

No stone left unturned to reduce weight, improve stiffness and surfing response!

Aproximate boat weight --- sub 7kg

Sea Kayaks

Carbon Kevlar 1

Epoxy deck and hull

Deck is: Lightweight sprayed gel coat on E Glass deck
Hull is: Lightweight sprayed gel coat on E-Glass with special core and an inner layer of Carbon Kevlar.

Aproximate boat weight 23 - 26kg

Super light:

Oven cured Epoxy deck and hull
Deck is: Lightweight sprayed gel coat on E Glass x 2
Hull is: Lightweight sprayed gel coat on E Glass x 2 Carbon Kevlar x2 with special core ( inner layers Carbon Kevlar).
Hull is now vac bagged !

Aproximate boat weight 20-24kg

X-tech:

Oven cured Epoxy deck and hull
Deck is Deck is: Lightweight sprayed gel coat on E Glass x 1, Carbon x1
Hull is Vac bagged Carbon x2, E-Glass x1 with honeycombe core /foam core ( inner layers Carbon Kevlar).

Hull can now be coloured or bare carbon kevlar (No cost option)

Aproximate boat weight 17- 20kg

Carbolite Pro

Oven cured Epoxy deck and hull
Deck is: Lightweight sprayed gel coat on
Vac bagged Carbon x2 with a very special core.
Hull is Vac bagged Carbon x3 with honeycombe core /foam core ( inner layers Carbon ).

Aproximate boat weight 14- 17 kg

Elite
Featherlite spec

Materials used , Carbon, Carbon Kevlar and Carbon Dyneema.

Rolled and intergrated cockpit rim with special thigh braces.

No stone left unturned to reduce weight, improve stiffness and response!

Aproximate boat weight --- sub 12 - 15 kg depending on model.

Canoes

Glass

Hull is: Gel coat on E-Glass with special core

Beautifully finished Ash gunnels and seats

Aproximate boat weight 24-26kg

Super light:

Hull is: Lightweight sprayed gel coat on E Glass x 3 Carbon x1 with special core ( inner layer Carbon ).
Hull is now vac bagged !

Beautifully finished Ash gunnels and seats

Aproximate boat weight 19-23 kg

X-tech:

Hull is Lightweight sprayed gel .Vac bagged Carbon x2, E-Glass x1 with Epoxy compatible core ( inner layers Carbon).

Aproximate boat weight 17-20 kg

Carbolite Pro

Hull is Vac bagged Carbon x3 with foam core ( inner layers Carbon or carbon kevlar).

Hull can now be coloured or bare carbon kevlar (No cost option)

Aproximate boat weight 16-19kg

Elite
Featherlite spec

Especially for the weight weenies out there. The closest thing to an F1 spec we can think of!
This is a full epoxy vac bagged special build!

Pure Carbon finish hull with foam core . It looks absolutley stunning !

Materials used in the boat build are, Carbon, Carbon Kevlar and Carbon Dyneema.
It's as high tech as it is possible to get!

The Gunnels are Pure carbon, the seals and end caps pure carbon.

No stone left unturned to reduce weight, improve stiffness and response!

Aproximate boat weight --- sub 12-14kg depending on boat size and seats

Polo Kayaks

Club

Kit you club out , super tough and durable .

Lightweight sprayed gel coat on E-Glass with special core in hull and an inner layer of Diolene.

All epoxy build

Aproximate boat weight 12kg

Team Spec

A spec for club team members on a budget , Strong , light and durable.

Lightweight sprayed gel coat on E-Glass and carbon kevlar with special core in hull and an inner layer of Carbon Kevlar.

Vac bagged hull

All epoxy build

Aproximate boat weight 9kg

Carbolite Pro

A spec for competing at the highest level

No stone left unturned to save weight, improve stiffness, response.

Aproximate boat weight 7.5kg

Rock hard carbon Pro

A spec for competing at the highest level

An awesome "Rock Hard" build of Carbon bonded with reinforcement material and foam core . The deck and hull are vac bagged
No stone left unturned to Increase strength and save weight, improve stiffness, response and durability.

Aproximate boat weight 10.5kg

* Boat weights quoted can be greatly affected by colour choice , design and other factors such as ambient temperature on the day of manufacture. Because our pigments are lead and cadmium free some light colours and designs may require more layers of gel coat. If a low weight is a specific requirement to you we can advise you on the best way to make your color scheme work .

Please bear in mind that the appoximate weights quoted are our desired outcome weights , we cannot and do not guarrantee a finished weight and can only do ou best to work towards the weights quoted.