Gluing the Shafts Together and Finishing
I like to do most of the work before gluing the scarf on the shaft together. This just keeps the parts easy to handle while doing the work.
Kayak Paddle
Glassing the Blades
It is amazing how much strength a layer of 2-ounce fiberglass will add to the wood. Between the two and with the cord around the edge the paddle blade can absorb a lot of abuse.
Reinforcing the Edges
I regularly bounce my paddles off rocks. I want a rugged and durable edge to absorb the abuse. I have found that para-cord saturated in epoxy resin is very tough. While you can't exactly cut down a tree with these paddles, they will handle paddling in rock gardens or doing whitewater.
Sculpting the Blades
This is the hardest part of the process. I use a right angle grinder to do some freehand shaping and then refine the shape with hand tools. I try to make the edges of the blade nice and thin to keep the paddle light, while leaving the central section of the blade full thickness for strength.
Gluing on the Blades and Initial Shaping
Even though the blades of these paddles may be feathered, they are still glued on straight and square on the shaft. It helps to cut away some of the shaft on the power face of the blade before gluing on the blades, but this is not required.
Preparing the Shafts - Scarfing and Tapering
Most of the paddles I make are feathered. This means the blades at each end are at an angle relative to each other. This can relieve some stress on the wrist when paddling and help cut through a headwind.
Cutting the Blades
I use a jig I made for the band saw that helps cut a curved blade, but you can just mark the curves onto your blade blanks and make the cuts free hand.
Making Kayak Paddles - Preparing the Blanks - E1
The blades will be cut out of blanks that are 16"-18" long, about 4" thick and at least 4" wide. With wider blanks you can make more blades.
Making a Wooden Kayak Paddle
The YouTube videos are a step-by-step guide to making kayak paddles using laminated wood. The first video focuses on preparing the raw materials, with explanations of the types of wood and their properties as well as how the pieces will be cut and glued together. The second video covers the creation of a jig for cutting the paddle blades into their final shape. The third video explores the process of cutting and shaping the shafts, including how to make a scarf joint for feathered paddles. The fourth video covers gluing the paddle blades to the shaft, and rough shaping of both. The fifth video delves into the finer details of sculpting the paddle blades, using a variety of hand tools and power tools. The sixth video shows how to create a reinforced edge using nylon cord that will be later covered in fiberglass. The seventh video demonstrates glassing the blades, including the process of applying layers of fiberglass cloth and epoxy for strength and durability. Finally, the eighth video outlines the finishing touches of assembling the feathered paddles, shaping the shafts, and sanding them in preparation for applying a clear coat.
