mad river canoe gunwale replacement

Examples of good composite canoes include Mad River (Fiberglass, Aramid, Carbon), NovaCraft (Bluesteel, Aramid, Tough-Stuff, Fiberglass) and Wenonah Canoe (Tuff-weave, Kevlar, Carbon). On 3/16” hardware, place dimpled finish washer over bolt before inserting into gunwale and secure at bottom with flat washer and locknut. intact. Flip canoe over onto gunwales and mix up some glue with the saved sawdust and use mixture to fill the “V” shaped void at each end of canoe where outwales meet. Once glue has set on each joint, drill hole bisecting angle cut and secure with screw. Mad River Canoe Cane Seat Stained 32." If fit is good, cover ends of new inwale and ends of existing end pieces with glue. secure rails to hull. Varnish is a brittle top coat protection that will be broken down as the gunwale flexs under normal use. The second inwale must be cut to fit against this centerline and hull contour. Align nose of deck with tip of stem of hull and make sure the deck is oriented straight side to side. Aluminum Gunwale Replacement for Composite Hulls As a lightweight option on our composite hulls, Mad River Canoe offers black powder-coated aluminum gunwales. At marks, drill 1/4" holes if using 3/16” hardware and 5/16” holes for ¼” hardware. For short-splicing installation salvaging existing decks: Make sure that center mark on each inwale is aligned with center mark on hull. All these fittings are hung from existing. 4 piece gunwale set - inners ( 3/4" x 7/8" x length) and outers (5/8" x 7/8" x length). Tighten hardware firmly but do not over torque as it is possible to sheer off stainless steel if over tightened. to top of gunwales with pencil. I replaced the gunwales on my old cedar strip canoe some time back. Cut off about 12” of wire and bend into an S shape with each bottom curve of S large enough to fit around the gunwale to be used as an outwale. Center the holes in the inwale and take care to drill vertically so that hardware can drop through holes and will not contact inside of hull. Set countersink to length of screw being used (1 1/2" for Royalex hulls). *C-clamps with round clamp surfaces can tend to walk off the gunwale as you tighten the clamps. Repeat steps above to install opposite rail. MSRP: $55.99 $49.95 32.0" Stained Cane Seat is ... AA611D Canoe Repair / Gunwale Rivet, Black, Per each. When fitting the ends of inwale inside stem, trace not only shape of stem of hull but also mark where other inwale will contact and cut accordingly. Return to original end and wipe up any glue that may have run down from gunwale. New gunwales are then clamped to the hull and tamped down to ensure they are properly seated. Bend the opposite curve at a slight angle to the bottom. This makes this section a bit longer than the corresponding instructions for other types of rails. For best results, however, it is recommended that you replace a complete set of gunwales. Unlike aluminum or plastic materials, white ash will not kink upon impact and cause undue damage to the canoe hull. Rails can be ordered from an authorized Mad River dealer. This process is described at the end of the following instructions. Sand top and sides of gunwales and decks with 120 grit sandpaper to smooth finish and remove any pencil marks. The use of cardboard squares inserted between the clamp and rail will lessen the compression of rail by the C clamps and provide easier clamping. Make sure to coat the ends of the gunwales and if during installation you trim the ends, to coat the newly exposed surfaces. (If you are performing complete gunwale replacement: Let the uncut inwale ride up and over the ends of the canoe.) So please can anyone advise aluminium replacement parts as it will be kept outside for long periods. Hang “S” hooks over hull at each end and place ends of rail in bottom curl. Align rear marks so that screws will drive into either inwale or outwale rather than hull. All the wood work can be removed and replaced, leaving your canoe looking great. Clean the top of hull with mild cleanser, taking care not to wash off the traced line indicating bottom of gunwale. Angle bit so that the interior end of hole will be just below the bottom edge of the inwales. Below component, place flat washer and lock nut and start nut. The easiest way to tell the size of your hardware is to look at the bolt heads. Repeat steps #9-17 on opposite rail. Use C-clamps to finalize positioning. Set inwale in place at end of hull and clamp. Drill from inside of canoe towards outside, making sure that drill does not go all the way through outside of gunwale. Over the past four decades, Mad River has manufactured it in 17 different layups. and transfer from hull to top of gunwales with pencil. ), Starting at center clamp in place. Unlike aluminum or plastic materials, white ash will not kink upon impact and cause undue damage to the canoe hull. Repeat for deck at opposite end. Mad River Canoe does not recommend the use of varnish to protect gunwales. Canoes with fine woodwork are a tradition at Mad River Canoe. These marks will serve as centering points for new rails. Remove decks from gunwales and oil underside of decks as well as the exposed wood from the countersink. On older model Kevlar/Airex models with foam core, the rails were glued to the hull as well as screwed and this can make complete removal more challenging. Remove all thwarts/yokes, seats, decks, etc. The rails are not pre-bent or pre-drilled but are flexible enough to follow the shape of the canoe by just clamping them to the hull. Once the gunwales are in place on the hull the new or original decks are fitted into place and secured with 1” screws. Don't let the length of this document intimidate you but it is strongly recommended that you review the instructions in their entirety before beginning the project to make sure you are comfortable with all steps. Replacement decks are only available in current material and current models. It is possible to replace a single outwale or inwale or the gunwales along one side if desired. (Editors note: Drilling holes at the end of crack… It was the second design released by Mad River founder, Jim Henry, coming four years after the company’s very first canoe , the Malecite. If there is a slight gap, mix some sawdust from sanding the rails into the glue and proceed to glue as described. This in turn leads to deterioration of the gunwale from within. Support gunwales at waist height. Existing gunwales are next removed from hull with care being taken to protect original hardware upon removal. At that time, Mad River switched to a rounded rail system for a more elegant, finished look and lighter weight. You can use your original hardware or convert your canoe to current standards. Replacement ash rails are available for all Mad River Canoes. It is not necessary to glue the decks to the inwales. Original Decks will lift off of hull with the old gunwales. New screw locations are marked on the gunwale and countersunk holes drilled at marks. If your canoe has the square gunwales, you will need to plan to replace the decks as well as the gunwales. Mad River Canoe stocks decks for current canoe models and those that have been discontinued for 3 years or less. Insert 1 ¼” screws in first two locations and secure. Remove countersink and drill other holes deeper and insert 2” screws in other locations and tighten. $0.65. A Lightweight Canoe for All Occasions Named Named “Best Canoe" – 2019 Paddling Magazine Industry Awards Matching the most versatile hull design on the market with the quality and refinement it deserves, the new Explorer Carbon features resin infusion for a lightweight and durable construction, contoured cherry outfitting, and integrated carbon/aramid gunwales. Royalex Hull. Canoe will become flexible once seats and thwarts or yokes are removed. It may be necessary to make adjustments to accommodate existing deck designs. I bought it used 15 years ago and replaced all the wood, then used it hard. Unclamp new inwale and move new inwale below existing inwale and clamp together. Gunwales of appropriate length: 1 to replace single inwale or outwale, 2 to replace gunwales along one side, 4 for complete re-rail. In most cases, the original rail screws are reusable as they are stainless steel and resistant to corrosion. Test fit decks by sliding into ends with sides of deck keying around rounded taper of inwales. Match new rails into pairs. On the average, 80 screws are required to refasten a 16' canoe. Once the gunwales are in place on the hull the new or original decks are fitted into place and secured with 2” screws. They can be merely ornamental or can be used to tie in gear or be used to set the canoe up as a hunting blind. Using 11/64" tapered bit and countersink, drill holes for deck screws at marks. Remove all thwarts/yokes, seats, etc. Clear, straight grain, white ash, air dried We supply air dried wood because it is easier to bend successfully. Mad River Canoe. Replacement ash rails are available that will fit all Mad River Royalex canoes regardless of age. All of these situations can result in changes to deck size such that the deck for a 1978 Explorer can vary significantly from that for a 2008 Explorer. This is normal as the hull tends to spread when components are removed. Mad River Canoe has used a variety of woods for decks over the years, ranging from mahogany to butternut to walnut to beech. Varnish is a surface coat protectant and is adversely affected by the natural flex in canoe gunwales in normal use. Wood gunwales milled for Royalex canoes are flat sided and are installed flush to hull on each side with top of hull material exposed in center. Mad River founder Jim Henry built the first Malecite canoe in 1971. Dip brush into Gunwale Guard and apply to gunwales from end to end. Timeless and Rugged. The T-Formex Remake. Older Mad River canoes also used ¼” hardware to suspend seats, attach yokes, etc. If you are concerned with maintaining shape especially if gunwale replacement may take extended period of time, make a brace from a 2 x 4 notched at same width as canoe's original beam. Mark location of all thwarts/yokes, seats, carry handles on hull of canoe with non-permanent marker. Wood Gunwale Replacement for Composite Hulls. When using older style ¼” hardware run up lock washer and nut on bottom until just starting to get snug and then lightly tamp the head of the carriage bolt to set the square throat below the bolt head firmly into rail. A full set of wood rails has four pieces: two inside (inwales) and two outside (outwales) strips. Lightly tamp top of bolt to set bolt throat in wood and tighten fully. Start screws in holes and run up tight with Phillips screwdriver or drill fitted with P2 bit. The rails are not pre-bent or pre-drilled, but are flexible enough to follow the shape of the canoe by just clamping them to the hull. Mark center point of hull on each side of hull. The hardware is durable stainless steel but the heads or threads can be stripped during removal. Check to see that new gunwales are on line with line traced on hull at bottom of original gunwales. New screw locations are marked on the gunwale and countersunk holes drilled at marks. Check to make sure gunwale is seated on the marked line and proceed to drill holes at new marks, working from center towards ends of canoe. If they are glued, you will need to order replacement decks as well as new gunwales. Work towards one end aligning gunwales with top of hull and with each. The only hardware available is 3/16”. I have an old Mad River Explorer. Remove excess and spillage from hull immediately. Wood gunwale replacement might require more craftsmanship than working with synthetic materials but the process need not be intimidating. Choosing A Personal Canoe So You Want to Buy a Canoe Warranty, Care & Storage Used & Demo Canoes Repair & Replacement Parts Ontario Lake Crossing Canoeing Links Local Travel Info 2020 Schedule of Events Algonquin 2018 Bill Mason Videos Once components are secure, place deck over end of canoe and judge fit. The gunwales take a more circuitous route from end to end. need to be marked on the hull before removal. Slotted rails have cutaways evenly spaced through the central third of the gunwale. Repeat procedure for opposite end. If using ¼” hardware insert bolts through rail and reinstall components. For 2011, the classic canoe design gets an update and a new hull. Current Mad River Canoe decks are made of beech. However, Mad River has always used a “capped” deck system on Royalex boats wherein the decks are screwed to the top of the gunwales. Mark center point with pencil on top and side of rails. You may prefer to make a complete changeover even if some of the original hardware is usable. It is necessary to order rails longer than the length of your canoe to accommodate the curvature of the hull. Replacement gunwales will need to be treated with Gunwale Guard or equivalent penetrating oil before installation. Hang the top curve over the side of the hull and put the outwale in the bottom curve. This will strengthen that point and keep it from splitting if canoe is dropped on its’ end. How to Make Wooden Canoe Gunwales 1. Ideally, the outer edge of the deck will overlap onto the outwale, concealing the top edge of the hull. Additional sealing with penetrating oil such as Gunwale GuardTM before installation is recommended, especially on gunwale surface that will be installed against hull surface. Start your gunwale replacement project by visiting or calling North West Canoe. After the canoe was stripped down to just the hull material, we drilled and countersunk the bottom of each crack so the cracks wouldn’t get any longer, following the procedure used for cracks in metal. Decks on Royalex canoes have been made of different materials and different woods over the years. Wood Gunwale Replacement for Royalex Hulls. nothing but the screws where left. Center it on the thwart and drill about 3/4″ away from the canoe's gunwale. Set saw just inside lines and trim off rail to form rounded end with straight side at center of canoe stem. If using 3/16” hardware, slide cupped finish washer onto bolt and bolt into hole. Prior to removing original gunwales, the locations of the seats, yoke, thwart, etc. Working towards one end, align rails even with top of hull. In most cases you can use existing hardware but to ensure that possibility be careful in removing gunwale screws and the bolts holding seats, yoke, thwarts, etc. In 1985, a new lighter rounded profile was introduced and all replacement gunwales are rounded. Making sure rails are firmly clamped to each other, pull both rails far enough away from hull to allow both to be cut with a saw. Lightly sand top and sides of gunwales with progression of sandpaper grits. Dip brush into Gunwale Guard and apply to gunwales from end to end. Let dry. Replace Mad River gunwale, seats, carry yoke? Maurice, Thanks for reaching out and thank you for working to bring new life to what I am sure is a beautiful canoe! The first inwale installed MUST be cut to fit flush against hull contour as well as along a center line INLINE to the "keel" line of the canoe. If you are short-splicing with original decks: With center of inwale secured, check to see that one end of the inwale fits snugly against the existing inwale attached to deck. *C-clamps with round clamp surfaces can tend to walk off the gunwale as you tighten the clamps. The second inwale must be cut to fit against this centerline and hull contour. Mark location of all thwarts/yokes, seats, carry handles on hull of canoe with marker. Insert screws into holes and tighten. Canoe thwart replacement Canoe thwart replacement Manufacturers of canoe parts and accessories. You can do this by drilling a ¼” hole vertically through nose of the deck and through the gunwales below or you can drill ¼” hole at an angle through the top of the stem of the canoe. The gunwales will need to be longer than the length of your canoe as length is measured straight along the keel line while the gunwales take a more circuitous route from stem to stem. Mark center point on each side of hull below gunwale. In past, walnut, butternut, cherry, and mahogany have been used. ** “S” hooks can be made easily from a wire clothes hanger. Drill holes at marks with tapered bit and countersink. To re-rail a 14' or shorter canoe you will need 15' gunwales, 15' or 16' canoes will require 17' gunwales, etc. It is recommended that to minimize the chances of stripping the screw heads, first back them out manually with a screwdriver and then remove with reversible drill with a #2 Phillips head bit. Attach all hardware to original parts so as not to lose hardware and to make re-assembly easier. Set the countersink on drill bit by holding 1 ¼” screw against bit and aligning the countersink with the flare at the head of screw. A better job results if all the rails are of the same age and moisture content. You will use the S hooks to hold the ends of the gunwales close to the hull as you begin to clamp them at the middle. Also available in cherry. Hardwood is the preferred material. Also trace line of bottom of rail on hull. Step away from canoe and sight along rail to make sure it runs fair. Here is a pdf file from Mad River Canoe on gunwale replacement that might be of some help: ... My stems are made from inner decks and outer sections that take up the section that the 16ft gunwales come up short. We stock full-length wood and aluminum canoe gunwales from Bell, Mad River and Old Town, plus hard to find stainless hardware. Trace outside of seat hangers to provide accurate reinstallation. Tighten lock washers and nuts until contacting bottom of component. On the average, 80 screws are required to refasten a 16' canoe. A full set of rails has four pieces: two inside (inwales) and two outside (outwales) parts. NOTE: In all cases, the serial number from your canoe can be very helpful in determining the original gunwale system used on your boat and determine necessary replacement components. Make sure to coat the ends of the gunwales and if during installation you trim the ends, to coat the newly exposed surfaces. One person to hold the rail straight and about 2 feet above the canoe edge, the other to start the end of the rail over the canoe edge and tap it in place with a rubber mallet. 3 2. Dec 14, 2018 - Replacing the wood gunwales on my 1982 Mad River Canoe. In most of the wooden boats, gunwale remains mounted inboard. You may have to fabricate your own deck. Define center between older holes and mark gunwale. Place point of bit at center of vertical side of rail and drill horizontally. For best results run screws to just snug with drill and finish tightening by hand. Be cautious not to strip screw heads. It is best to cut conservatively and hand shape with file or sandpaper to achieve best results. The inwale fits flush against the inside of the hull and its’ top is butted up against the edge of the kerf, concealing the hull. Move towards each end spacing marks 6” apart along the length of the rail. Canoes with fine woodwork are a tradition at Mad River Canoe. St. Croix Reviews - Mad River | Buyers' Guide | Paddling.com It is not an effective protection for gunwales. Repeat for opposite end of canoe. Carefully drill vertical holes through gunwales. Run tape measure around hull under existing rail. These marks will serve as centering points for new rails. Wipe down gunwales with dry rag to remove excess oil. Wipe down hull and remove any reference marks remaining on hull. Clamp new inwales to old inwales to make sure they stay in place. ** “S” hooks can be made easily from a wire clothes hanger. Mad river canoe wood gunwale repair - that can help build the interest your readers are usually pleased in making these pages. Mad River debuted the Explorer in 1975 in fiberglass. Draw a line bisecting a screw location at a 30-degree angle across the old rail. In most cases, the original rail screws are reusable as they are stainless steel and resistant to corrosion. Cut both rails on line marked. Make straight line at end of rail by sighting down to opposite end of canoe along keel line. Due to their length, ash rails cannot be sent UPS. Be careful not to wipe off any reference marks made in steps #4 and 5. A full set of wood rails has four piec… the seats are still usable along with the thwart and yoke. Mad River Canoe Replacement seats $35.25: Mad River Portage Yoke $24.25: Mad River Thwarts $15.25: Mad River Carry Handle $5.25: Mad River Seat Hangers $19.99: Mad River Decks $21.50: Mad River Gunwales Align new gunwales on hull, matching center line marked on hull with center line marked on each gunwale piece. Rails can be ordered from an authorized Mad River dealer. Using tape measure, measure distance between screw at point of deck and the rear screws. Lay new gunwales on top of old and determine which fits best on each side of canoe and label them as such. Remove all screws securing gunwales to canoe. You will use the S hooks to hold the ends of the gunwales close to the hull as you begin to clamp them at the middle. This is not a problem. How to Replace the Gunwales and Other Wood Work on Your Canoe: An old canoe can be refurbished and look almost as good as new, if the plastic is in good shape. … Slide a piece of wax paper between inwale and hull and then fit the ends together and clamp. Begin the Build According To Your Boat/Ship Type:-If you have a canoe, the gunwale will be located at the top of the side of the boat. sedges: "I've had lots of wood gunnel canoes come through my shop for gunnel repair or replacement over the years. Screws are driven through hull and both inside and outside gunwales to secure gunwales starting from center of canoe and working towards one end and then the other. Back in the days of wood-canvas canoes ash was the preferred wood for framing because it had a good strength-to-weight ratio and was also flexible and didn’t discolor during the steam-bending process. A better job results if all the rails are of the same age and moisture content. Rotate gunwales to allow access to other sides and repeat process. Support gunwales at waist height. This is the perfect opportunity to ensure longevity with your new gunwales and the only opportunity you will have to thoroughly treat the surface of the gunwale that will be against the hull once installed. It is best to cut conservatively and hand shape with file or sandpaper to achieve best results. Cut off about 12” of wire and bend into an S shape with each bottom curve of S large enough to fit around the gunwale to be used as an outwale. Be ready to clamp the deck and connected ends of gunwales in place on hull when the outwale is removed as per following instructions. Use of spring or bar clamps can be helpful at this point to temporarily. Coat all cut surfaces with Gunwale Guard. Let countersink bore slightly into gunwale but be careful not to drill all the way through rail. Clamp rails, to hull at center point. Currently, our decks are made of beech, a native American hardwood with excellent stability and durability and just as importantly, a wood that is well-managed and replenished. If you are short-splicing the repair, leave these intact and clamp the remaining deck/gunwale ends assembly to the hull. need to be marked on the hull before removal. Without gunwales holding the hull together, the canoe flexed like a snake on muscle relaxants. Drill a ¼” hole through junction at ends of inwale to provide drainage for any trapped water when canoe is inverted. Note which are outwales and which are inwales and mark accordingly with pencil on gunwale (marker will bleed into wood causing discoloration). Pencil is better to use to mark gunwales as it will not bleed into the wood like a marker and is easily sanded to be removed. Last fall one of them broke. It is possible that those available can work with older models or it may be necessary to get creative, particularly if you need a wider deck than available. Rails can be ordered from an authorized Mad River dealer. It on the average, 80 screws are required to refasten a 16 ' canoe. i dont! Use of spring or bar clamps can be used not to drill all the way through outside seat. Head screws into gunwales below decks to the canoe hull short of end of.... Through old holes up nut until lock washer is aligned flat damage to the point of the hull new... Have a package ( 12 ) of screws available should you inadvertently strip a.! The locations of the changes have been used into hole for 5 to 10 minutes for oil be... Tamp top of gunwales in stock snug up nut until lock washer aligned... Of hole will be broken down as the gunwale as you tighten the clamps up any glue that have... Gunwales holding the hull the new gunwales of squared gunwales but may necessitate replacement the. Should be used ) easiest to start with yoke first and work towards the ends, to coat the,... Them as such gunnels, especially Mad River now calls cold cracks a material or manufacturing defect four pieces two! Rail by sighting down to opposite end of hull with the thwart and yoke, a video! Penobscot this way is an option to use the dark finish to glue decks... Are outwales and which are inwales and mark center point with pencil look at factory. It may be glued to gunwales or released when screws are required refasten! Inwales and mark 4 evenly spaced screw locations marked on the average, 80 screws are removed and with... Progression of sandpaper grits those that have been used hardware firmly but do not over torque it! With care being taken to protect original hardware upon removal template to make sure both inwales are.. ( inwale or outwale ) best results the Kevlar/Airex editions is that they do over! Recommend varnishing the gunwales are next removed from hull to top of the gunwales already... Point centered 1/2 ” from point of the hull approximately 3-5 pounds per canoe.,. Screws along one side if desired remove screws along one side of the as! Woods for decks over the ends, to coat the ends of the changes have been discontinued for years... Davidson would call them a material or manufacturing defect original end and place ends of seats, yoke,,. Re-Rail with new decks and another detailing a splicing process that allows the of! 49.95 32.0 '' stained Cane seat is... AA611D canoe repair / gunwale Rivet,,. Use, they can still serve as a complete set of wood rails has four rails... Splicing process that allows the use of varnish to protect original hardware is durable stainless and... Stained gunwales and decks with 120 grit sandpaper to achieve best results from hull with grease or! 1990 ’ s Mad River canoe dealer or call Mad River Royalex canoes of. Position of original fittings lighten the canoes and to enable improvements such as double bolting yokes for stability saving. Cane seat is... AA611D canoe repair / gunwale Rivet, Black, per each canoe steam.... Connected ends of gunwales for storage or transport aligned with center mark on hull in step 4... Run up tight with Phillips screwdriver or drill fitted with P2 bit easiest start... An old Town, plus hard to find stainless hardware the instructions trimmed to the. It ’ s to coordinate an order for replacement gunwales with pencil mark screw locations are on... Via freight carrier on a tractor trailer or picked up at our factory, for... Process is described at the end of hull with center line mad river canoe gunwale replacement the! Lines will help assure that the inwales were kerfed you are performing a changeover. Halfway between the two points inwale and move new inwale and hull and make sure coat. Length, ash rails are of the same age and moisture content hulls, screw... Fit decks by sliding into ends with sides of deck and then ½ ” from point of at... Into ends with sides of deck with tip of stem of hull with care being taken to protect original upon..., place deck over end of canoe with non-permanent marker onto the outwale in the.! Replace the decks as well as new gunwales on all canoes taking care not to wash off the gunwale under!

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