Custom Wood Kayak Toggles

The end toggles that I started in the previous post turned out... okay. Not perfect but they'll do.

Today I unclamped the laminated block and milled it by drilling a 3/4" forstner bit about a 1/2" down, and then drilling all the way through with a smaller bit. Then ran it through my table saw.

After working them on my stationary sander for a while, this is what I ended up with. They have had two soaks in teak oil so far and I'll put a few more coats on over the next few days to build up a nice layer. I didn't want to coat them in epoxy or varnish because wood this thick may still expand even though it's laminated. The oil should be fine for a season or so.

I also fine tuned the bulkheads after they had been fiberglassed and started to install them in the hull. I started by getting them lined up inside the hull just where I wanted them, and then running a Sharpie pen around the hull to mark where to sand. Then I removed the bulkheads and sanded the hull at the line. Also sanded the edges of the bulkheads since it has been a few days since the first side was laminated. I drilled two #60 holes through each of the small epoxy windows that I made in each bulkhead too. They will allow the air to equalize and not such the hatches down too much.

Then I inserted the bulkheads back in and tacked them in place with some small dabs of thickened epoxy here and there, being careful not to move the bulkheads. Tomorrow when it's cured I will be able to use more force and get a bead of thickened epoxy around the entire hull.

Peace!

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