Folding Kayak: A One-Sheet Plywood Kayak With No Metal Parts
Four plywood panels from a single 4 x 10 sheet, joined with canvas tape and contact cement: a clever one-person kayak with no metal anywhere.
Here is a kayak that starts life as a single sheet of plywood. Jess E. Rathbun's design cuts four 1/4 in. side panels from one 4 x 10 sheet, then joins them with canvas 'tape' and contact cement instead of screws or rivets. There is not a single metal part in it. Built for one average-sized adult, it is a tidy, thrifty project for anyone who enjoys clever material use as much as time on the water.
Folding Kayak at a glance
| Detail | Folding Kayak |
|---|---|
| Type | Kayak |
| Capacity | 1 average-sized adult |
| Construction | Four 1/4 in. plywood side panels from one 4 x 10 sheet, 'taped' with canvas and contact cement; no metal parts |
| Designer | Jess E. Rathbun |
| Plan sheets | 4 |
Why one sheet goes so far
The whole hull comes from four plywood panels, which keeps buying simple and offcuts to a minimum. Joining the edges with canvas strips and contact cement means no fastener holes to seal and nothing to corrode, a real plus for a boat that may spend time in damp storage.
With room for one average-sized adult, it is sized for solo outings on lakes and slow rivers. Five plan sheets cover the panel shapes and the taping method, which is the heart of the build. Without metal fittings, there is less to snag, rust or replace, and the build stays clean and quiet in a home workshop.
The original plan sheets
These are the 4 original sheets, scanned from the magazine. For building, use the full-size PDF in the download section below.
Who designed it
Jess E. Rathbun designed this folding kayak around a single 4 x 10 sheet of plywood. Its five original sheets lay out the four side panels and the canvas-and-cement joining method that replaces every metal fastener.
Before you build
- Mark all four panels on the 4 x 10 sheet before cutting anything, so a measuring slip does not cost you the whole sheet.
- Work the contact cement in a warm, ventilated space and press the canvas tape down firmly along every seam, since the joints are the hull.
- Try a few short trips close to shore first and check every taped seam for lifting before heading further out.
Download the plan
The full set of five Folding Kayak sheets in one file, panel layouts included, ready to print or open in the workshop.
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