How It's Made - Plastic Molded Kayak

in days gone by kayaks were made of wood

and animal skin and used by people who

hunted to survive fast forward to today

and you'll see the kayaks have updated

their image now they're marvels of

molded plastic coveted by sports

enthusiasts far and wide a kayak is

formed by the melting of plastic on a

mould of nickel this mold is made in two

parts an upper and a lower section the

surface of the mold is perfectly smooth

and has a mirror finish that guarantees

an excellent luster the graphics are

laid on the mold before molding begins

this way they're well impregnated in the

plastic it's an operation that requires

quite a bit of dexterity because

contrary to self adhering stickers these

graphics can't be lifted off if they

haven't been well positioned this is the

yellow powder they're going to melt

linear polyethylene it comes in several

colors the amount of powder to be melted

is determined by the kayak model to be


at the same time in other moles we're

going to fabricate other parts of the


such as the baggage compartment cover

the central support and the seats the

polyethylene is poured into the mold

which is then closed all the other molds

are closed as well

before entering the oven the molds are

securely closed with plants to avoid any

loss of polyethylene

the kite mold is put onto a transporter

and placed facing the oven because of

the large dimensions of the craft the

oven had to be custom-made the whole

kayak goes in the oven is 23 feet long

and has a diameter of about 6 feet the

polyethylene melts at 550 degrees to

completely distribute the powder

throughout the mold it pivots on several

axes it turns on itself while the oven

oscillates 30 degrees toward the front

and rear this procedure is termed rock

and roll and lasts 19 minutes cooking is

now over and the mold exits the oven but

the plastic has to cool in order to


to do this they place the mold in this

cooling chamber it must not be cooled

too quickly or at the forums a 16 foot

kayak can lose up to 6 inches of its


now the cover the mold is lifted off

then they unknown the cover and the

other small parts the kayak is finally

unmolding now they can proceed to


while inspecting the kayak and remove

any plastic bridges left by the joint

between the two halves of the mold they

now move to finishing this begins with

the screwing on of carrying handles here

they cut the opening for the baggage


and then they install the Trinity

the central support is positioned it

plays an important role because it links

the bottom and top portions of the craft

all that remains now is to finish the

baggage compartment they attach

fasteners then put the cover in place

and hold it down with a retaining strap

finally the kayak is packaged ready for

delivery this company makes 12 by 8

models of various dimensions