CLC Sail Rig - Chesapeake Light Craft Kayak Sail Rig MK II

I built this sail rig to go with my boat, Hull B. I built this project strictly from plans, and raw materials.  I also did things a little differently than CLC lays out. First, I used a different sail plan, with a jib and a mainsail.  I will also changed the way the crossbars (aka's) will be attached to the hull. Finally I built the floats (ama's) as hybrids, where the hulls were plywood and the decks were strip built.

Length:  12 feet
Beam:  10 feet
Weight: 40 lbs.
  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

  • 8/28/08 - The sail rig is complete!

    CLC Sail Rig 8/28/08 - The sail rig is complete!

  • A small hatch covers the spot where the mast goes.

    CLC Sail Rig A small hatch covers the spot where the mast goes.

  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

  • View of one of the amas.

    CLC Sail Rig View of one of the amas.

  • 9/13/08 - A system is built to carry the rig in one compact package.

    CLC Sail Rig 9/13/08 - A system is built to carry the rig in one compact package.

  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

  • CLC Sail Rig Mk2

    CLC Sail Rig CLC Sail Rig Mk2

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Click here for a video of the sailrig in action. Note: it may take a few seconds to load.
  • The first step is to trace the full sized patterns for various parts of the rig.

    Sailrig Construction The first step is to trace the full sized patterns for various parts of the rig.

  • 7/31/08 - Bulkheads and mast parter pieces are drawn onto a piece of plywood.

    Sailrig Construction 7/31/08 - Bulkheads and mast parter pieces are drawn onto a piece of plywood.

  • The bulkheads are cut down to shape.

    Sailrig Construction The bulkheads are cut down to shape.

  • The bulkheads are laminated together. Altogether, the laminated bulkheads equal about 19 mm. This is 10 more than the plans call for. I am doing this for extra strength for rough weather and for possible installation of nets later on.

    Sailrig Construction The bulkheads are laminated together. Altogether, the laminated bulkheads equal about 19 mm. This is 10 more than the plans call for. I am doing this for extra strength for rough weather and for possible installation of nets later on.

  • 8/3/08 - The bulkheads are sanded to their final shape.

    Sailrig Construction 8/3/08 - The bulkheads are sanded to their final shape.

  • A finished upper stern hull panel.

    Sailrig Construction A finished upper stern hull panel.

  • This is a lower hull panel.

    Sailrig Construction This is a lower hull panel.

  • The panel is cut and shaped.

    Sailrig Construction The panel is cut and shaped.

  • The port ama is loosely stitched together.

    Sailrig Construction The port ama is loosely stitched together.

  • Both amas are stitched up and ready for glue.

    Sailrig Construction Both amas are stitched up and ready for glue.

  • The port ama with the seams filled with epoxy.

    Sailrig Construction The port ama with the seams filled with epoxy.

  • 8/4/08 - The interiors of the amas are coated with epoxy for waterproofness. Also the seam between the panels was reinforced with fiberglass tape.

    Sailrig Construction 8/4/08 - The interiors of the amas are coated with epoxy for waterproofness. Also the seam between the panels was reinforced with fiberglass tape.

  • Sheer clamps are installed.

    Sailrig Construction Sheer clamps are installed.

  • Ledge on the bulkhead for the deck to rest on.

    Sailrig Construction Ledge on the bulkhead for the deck to rest on.

  • The starboard ama will have a hybrid strip deck.

    Sailrig Construction The starboard ama will have a hybrid strip deck.

  • The starboard ama bow.

    Sailrig Construction The starboard ama bow.

  • The second aka is laminated only 3 strips at a time.

    Sailrig Construction The second aka is laminated only 3 strips at a time.

  • The deck is finished on the starboard ama.

    Sailrig Construction The deck is finished on the starboard ama.

  • The port ama deck is stripped.

    Sailrig Construction The port ama deck is stripped.

  • Since I used old damaged strips for the decks, I had to fill gaps between them with epoxy.

    Sailrig Construction Since I used old damaged strips for the decks, I had to fill gaps between them with epoxy.

  • 8/8/08 - The decks of the amas are sanded smooth.

    Sailrig Construction 8/8/08 - The decks of the amas are sanded smooth.

  • 8/10/08 - Sheets of plywood and a piece of bloodwood are epoxied together for use as the leeboard.

    Sailrig Construction 8/10/08 - Sheets of plywood and a piece of bloodwood are epoxied together for use as the leeboard.

  • Fiberglass cloth is laid out on the decks of the amas.

    Sailrig Construction Fiberglass cloth is laid out on the decks of the amas.

  • 8/11/08 - The starboard ama deck is fiberglassed.

    Sailrig Construction 8/11/08 - The starboard ama deck is fiberglassed.

  • The leeboard is cut out.

    Sailrig Construction The leeboard is cut out.

  • Both ama decks are 'glassed and fill coated.

    Sailrig Construction Both ama decks are 'glassed and fill coated.

  • 8/12/08 - The undersides of the decks are fiberglassed.

    Sailrig Construction 8/12/08 - The undersides of the decks are fiberglassed.

  • The rudder and leeboard are sanded and ready for fiberglass.

    Sailrig Construction The rudder and leeboard are sanded and ready for fiberglass.

  • Both are fiberglassed.

    Sailrig Construction Both are fiberglassed.

  • The decks are epoxied onto the amas.

    Sailrig Construction The decks are epoxied onto the amas.

  • The amas are sanded smooth. Here you can see the difference pre and post sanding.

    Sailrig Construction The amas are sanded smooth. Here you can see the difference pre and post sanding.

  • 8/15/08 - The amas are sanded and ready for fiberglass.

    Sailrig Construction 8/15/08 - The amas are sanded and ready for fiberglass.

  • Glass cloth is laid out.

    Sailrig Construction Glass cloth is laid out.

  • The other ama is fiberglassed.

    Sailrig Construction The other ama is fiberglassed.

  • The hole is cut for the mast in the mast partner. It is also sealed with epoxy.

    Sailrig Construction The hole is cut for the mast in the mast partner. It is also sealed with epoxy.

  • Both amas get a couple fill coats of epoxy. The white line is not a scratch, it is a discolored section of the plywood.

    Sailrig Construction Both amas get a couple fill coats of epoxy. The white line is not a scratch, it is a discolored section of the plywood.

  • 8/18/08 - The bulkheads are reinforced with epoxy fillets. This completes the construction of the amas. I only have to sand and varnish them.

    Sailrig Construction 8/18/08 - The bulkheads are reinforced with epoxy fillets. This completes the construction of the amas. I only have to sand and varnish them.

  • The mast partner is attached to the forward aka.

    Sailrig Construction The mast partner is attached to the forward aka.

  • 8/19/08 - The akas and amas are laid out.

    Sailrig Construction 8/19/08 - The akas and amas are laid out.

  • After holes are drilled for bolts in the amas they are put together and laid on the kayak.

    Sailrig Construction After holes are drilled for bolts in the amas they are put together and laid on the kayak.

  • The mast is test fit onto the boat.

    Sailrig Construction The mast is test fit onto the boat.

  • The mast step is installed.

    Sailrig Construction The mast step is installed.

  • The akas are sanded smooth.

    Sailrig Construction The akas are sanded smooth.

  • 8/22/08 - The sail rig is set up!

    Sailrig Construction 8/22/08 - The sail rig is set up!

  • The akas get the first seal coat of epoxy.

    Sailrig Construction The akas get the first seal coat of epoxy.

  • 9/28/08 - A new rudder that will work with a tiller is being built.

    Sailrig Construction 9/28/08 - A new rudder that will work with a tiller is being built.

  • 9/29/08 - The wood for the tiller is fiberglassed.

    Sailrig Construction 9/29/08 - The wood for the tiller is fiberglassed.

  • 12/13/08 - After some sea trials a reinforced carbon fiber end cap was built as a rudder mount.

    Sailrig Construction 12/13/08 - After some sea trials a reinforced carbon fiber end cap was built as a rudder mount.

  • 8/26/08 - Everything has been sanded and varnishing has begun. A good view of the leeboard.

    Sailrig Construction 8/26/08 - Everything has been sanded and varnishing has begun. A good view of the leeboard.

  • The amas and akas get a couple of coats of varnish.

    Sailrig Construction The amas and akas get a couple of coats of varnish.

  • 8/27/08 - The decks of the amas and the lower side of the akas are varnished.

    Sailrig Construction 8/27/08 - The decks of the amas and the lower side of the akas are varnished.

  • 8/28/08 - All the pieces are in place.

    Sailrig Construction 8/28/08 - All the pieces are in place.

Click photo for slideshow of selected photos of the construction process.

Link to full construction gallery.