I got a hot tip this morning on a "Mad River Kevlar canoe" at a upcoming garage sale. I stopped in and dropped some names and told them that I dinked around with canoes as a hobby. Well......I came home with a 16.5 Mad River Malecite (1994). Hull is in excellent shape, but all the wood is dry rotted and literally falling apart. The seats are not bad (wood frames), but the cane is not great. I've played with hulls before, but not wood trim. I'd like to tackle this on my own. The gunnel work doesn't look too difficult....an inside/outside piece screwed together. Can I make these myself fairly easy and out of what wood???...or would it be easier to order them (ideas on prices???) or, after looking on internet, would it be smarter to get some aluminum trim made (range of prices???)
I'll try to get some photos taken to show you what I snagged. I'm not going to tell you what I paid for it.....cuz you will all really, really, really hate me 8^}

I bought a 16' ABS explorer in much the same condition last summer.

You can actually order gunnels from Mad River for your boat. I think they were going to run me a bout $200 delivered to my local dealer. I talked to a couple of boat repair shops, they were about $250 for the gunnels (not installed).

I have a friend who knew a guy who had some cherry wood in ten foot pieces. We cut them to size on the table saw, routed them with a round-over bit, then scarfed them to make them long enough. I then oiled them pretty well.

I think I might have had a topic on here about them, you might search 'gunnels' and see what was said...

You can buy them but they won't be much different that what you can make (or have made) yourself. In fact when you consider shipping etc, the ones you make will be considerably cheaper. Basically they are 3/4" x 3/4" strips, rounded over with a router. Then just drill and counter sink holes and cut to length. You may need to scarf and that will probably be the hardest part and the thing you want to take the most care with if you want it nice looking.

Ash is probably the most common wood used, but you can use all kinds of things.

I had some made for me at a wood shop. I went looking for ash for gunnels. When I told them what I wanted it for they actually got excited. They had a few 10' lengths of ash 1.5 wide that they didn't know what to do with. It was scrap from another project. They didn't want to throw it away, but had no use for it. They ripped it to width, cut scafs, and rounded it over for me while I waited -- took maybe 15 minutes. Charge me $25 for 8 10' pieces!!

I doubt anyone else can get that lucky, but if you have any wood shops or furniture manufacters, etc in your area, it might be worth checking out.

Oh! I just remembered. I also got a bunch of 1" x 2" (actual measurement) of 8' red oak from a furniture place for free. I made a lot of seat frames from them (seats were made of webbing). The wood was not flexible enough for gunnels, at least that is what I first thought. I wound up slicing some 1/4" thick. This help them to bend. Then I laminated gunnels right on the canoe, one layer at a time -- three layers to 3/4". That worked very well.

While you're doing this, I'd replace all the wood parts. Get it all to match. It will be a fairly quick project.

Thanks Winemaker...I went out and took some pics...

Nice! She is going to clean up just fine. It will be a great project and be done fairly quickly.

Nice.

awww...come on doc. we can take it. $$?

Checkout northwestcanoe.com, they have everything you need AND detailed instructions. It will look factory new when you are done.
Looks like a great find, perfect for Lilcowdoc to use(thanks Dad).
CB

Not affiliatd just a Happy Customer!(I get all my building supplies from them)

Just knowing he won't tell us the price makes me hate him (a little).

Yeh PERFECT ;) for lilcowdoc...thanks Dad!

Woodfinder.com, a great way to find hardwood lumber suppliers in your area. Ash is traditional and bends well, cherry is always pretty, a little less dense than ash and a little lighter in weight, tjhough more expensive. You might get lucky like Bannock did and find a "remnant" that would work out for you. woodfinder.com

eds canoe

How cheap Doc? It's killin' us! Looks like a little money and a few hours will make a jewell. It's always good to see something save/restored to usefullness. Congrats. (Now, whadaya got in 'er Doc?) :)

ok.....the sweet old lady wanted the 2 BB bent shafts to go with it and she wanted $20 apiece for them. (like new btw) So....for 2 paddles and the canoe......I gave her....$175.....
She thought the woodwork looked so bad, that at first, she said if I bought the paddles that I could just TAKE the canoe. I told her that I could salvage it and that I would give her something for it. She was very happy with my offer!

I think you will be very pleased with your purchase.

The Malecite is perfect for pleasure paddling in near by lake. You can turn it around and paddle it as a solo from the bow seat, but it really needs weight in the stern (front now) or you weathervane in the slightest wind.

I had one but sold when I moved up to the Mad River Explorer as my tandem.

I now have a couple of grandsons getting to the canoeing age and would buy one in a heartbeat as it is perfect canoe to paddle yourself with a small person in front.

Great deal doc! Offering her the "guilt money" was a good move. Now you'll be able to sleep tonight :)

I live by the "What would Snakecharmer Do" motto ;)

Excellent! You, the sweet old lady, and the canoe will all be better off.

"guilt money" should have been atleast 500. i hope you dont sleep at all.....

zzzz....zzzzz...zzzzzz....zzzzzz

i think he will sleep fine knowing that the canoe will go to a good person (lcd as she seemed to have told me earlier today) lol

Old wood is all off and I found some nice Ash boards. Yoke was "pulpy" on one end so I'll find a new one, seats appear OK but the cane is iffy. I may order new webbed seats or I may try putting webbing on these. Hull has been sun bleached a little more than I thought. I may re-epoxy it. The wheels are turning....

Looks like a good spring project Cowdoc.

Hey CowDoc,

Before you epoxy it, try getting some boat-wash from a local marine shop, make sure it has oxyalic acid in the ingredients. I had a glass boat that was a bit bleached and used some of this on it an it improved a good bit. Then I used some rubbing compound, elbow-grease, and it shined up to about 80% of new. Easier then a skim coat of epoxy maybe...

humm?

Agree with winemaker, you do not want to epoxy over gelcoat. Try buffing out a bit in spot. Any boat shop will have some 3M gelcoat rehab products.
CB

WM and CB, I've been trying to research this layup and what I can do to resurrect it. The guy at Rutabaga said these were thin gelcoats that were laid in the mold and then had the kevlar pushed in and then had colored epoxy smeared in from back into one big homogeneous hull. It does not, and I don't think it ever did, look like a typical hard, shiny gelcoat. You can still see the kevlar cloth patterns, not bare threads, just the pattern. I was at Rutabaga yesterday and talked to a guy about it. He said if it had enough sun damage, which I'm starting to think it did, that the "gelcoat" almost literally "bakes off". I'm leaning towards the epoxy not so much for the looks, but to stiffen and strengthen this hull up a little. I'll try to take some up close pictures so you guys can see what I mean. Because of it's age and the changes at Mad River, nobody seems to have a hard answer for me. You guys may be my best bet! I did get all the Ash boards planed and ripped last night. I have about 10, nine foot sections of 3/4 x 3/4 stock to start scarfing. I have to find something for the decks yet. I also bought two contoured web seats (Ed's Canoe models) Thanks for all your ideas....I need all the help I can get.

On the bright side you have plenty of surfess area to try different methods. Another option is some Spar urathane. Give it a good sanding 220 grit and a couple coats.
CB

I've had issues with spar varnish curing over fiberglass or kevlar. It really seems to need to soak into the wood to cure properly. I'd go with an actually marine varnish (a marine supply should have it) also, here's a nice diy on varnishing a canoe by redrock which may help

refinish canoe

I took your hull photo and blew it up, I was encouraged by what I saw. The bleaching does not appear to be uniform, but almost vein-like, so the boat-wash might take it off if it is a chalking rather then a uniform bleaching. Rubbing compound might help some too, but beware of over doing it. I had a friend that buffed right through the gelcoat on an old wenonag jensen in an effort to return it to like-new, it can't be done with old colored gelcoat in my experience.

Older composite hulls are nt as silky smooth as newer boats, I do not understand why. An old 18-footer I owned had a bit of roughness or irregularity I could feel with my hand across the hull.

I agree that you have the time and opportunity to test a few ideas on the bottom of the boat to see the results and choose the best option.

You still got a great boat at a low price an no worries about that first scratch!

Agree with mwd1976,that's why I use spar urethane, specifically Minwax Helmsman. Spar varnish will never cure over epoxy or vinylester resins or polyexter resins.
Back when epoxy was NOT stabilized we put Minwax Helmsmans on to finish the canoes for UV protection. Now the epoxies are UV stabilized so this additional step is not required.
Minwax and Varethane are to that I know of available.
CB

Joe also has a thread about refinishing a SR 16 that sat out for 8 years or so that had lichens growing on it. He sands and epoxies that one. Its on the bottom right of his main page you may have to search a bit. redrockstore.com

I e-mailed NWcanoe. They said to work it over with a Marine Rubbing Compound and then 2 coats of spar urethane. You guys were right on! Thanks

Cant wait to see the pics when she is done.
CB

Me too! Sounds like your getting some great advice there doc. :D Thanks gang!

Here's an idea to brighten up the gelcoat. I did this on an Old Town Canadianne with very good success. The bottom of the Canadianne was badly scratched and was almost white because the gel coat was gone.

I mixed up some epoxy and added green colorant to it. I then used a roller to put a thin coat on and then hand rubbed it on to the canoe using a rag and acetone. The acetone makes the epoxy very running for a short period of time.

Project has been dead awhile (just worked 7 days and 3 nights). The homemade gunnels turned out to be a disaster with the wood I found. Ordered a Knockdown kit from Eds Canoes. It arrived today...glueing it up tonite. Played around with some hull ideas today. Airplane buddy had some Boston Maroon colored dope that we mixed with epoxy. Color match is awesome...just have to see if it sets up ok. I smeared some test patches on the stem, keel area. I'll check it tomorrow.

ok...worked on the canoe this weekend and tonite. The hull is done. Cleaned it, lightly sanded and applied one coat of the colored, thinned epoxy. I also applied some skid plates. Tonite I sanded down the skid plates and wet sanded the hull with 320grit. Then I applied a second coat of clear, thinned epoxy. Here's some before/after pics.

looking great cowdoc!

nicely done doc!

Very nice job, doesn't look like the same canoe.

Shiny. :D

Great job, doc. Pity you have to give it away. ;-)

looks dope doc!

Awesome!

Almost race ready now Doc. Nice work.

Nice transformation doc! It's remarkable what a person can accomplish in between Spotted Cows :)

during....

Looks great CD, almost hurts to think about that first love scratch.
CB

looks a lot better than when i first saw it doc. nice job

Great Job!

Boy, LCD is reeaally gonna like her gift when it's done!

Hey CD, what did you thin your epoxy with?

The boat looks great, I would be curious as to how well the new finish holds up over the first few trips. Its clear you did a right job prepping and applying, but my experience with 'skim coats' of epoxy is they tend to be easy to scratch or mar.

I comment not to condemn, I have an old FG boat I have considered trying to improve the looks of and I am looking for a way to accomplish this, I hope your method works so I can steal it...

humm?

Cowdoc,

Now that you you have restored it, you can make a quick buck off of it!

http://minneapolis.craigslist.org/boa/1116070699.html
(want to buy a canoe like yours...)

Seriously - very nice canoe.

H

Nice work! What type of epoxy did you use and what did you thin it with?

Thanks for sharing.

Mongo like pretty colors!

Call the folks at North West canoe in Minneapolis, Mn. and tell him what you've got and they'll put together what you need. NW Canoe sells a complete re-railing kit that has everything. Also do away with the cane seats and get the web seats and seat hangers if needed. If needed get another portage yoke too. If the hull doesn't have skid plates I'd do that too. All of this is very easy to install and they send insructions to do so. One thing I might recommend is that I marked the locations of the yoke and seats on the side of the hull for proper spacing. Also note which way your portage yoke faces.

For about very little you can have as good as new $2500 boat.

I speak from experience as I have replaced the rails & seats on my 1981 MR Kevlar Explorer 3 times in 27 years. My boat has been to the Quetico many times.

I live in Kentucky and my stuff came from them. You can save the shippping cost by driving up to see them. Call ahead and they'll get it all together for you.

Good Luck

I got the gunnel kit from Eds Canoes, along with a new yoke. Already picked up the web seats. Skid plates were installed when I redid the hull. Seats and yoke placement are already marked with tape on the hull. I'll wait to cut the length of the new carry handles after I see where the best place to locate them after screwing inwales to outwales. New deckboards are glued together, waiting to be planed, cut to fit and epoxied in.

Gunnels are all in place and the decks also. On my next day off I'll put the seats, handles and yoke in.

Wow that really looks sharp. It could use a few more clamps on pic two if you ask me.


Just kidding looks awesome

Envious of how terrific some folks are with their hands. Great job.

I'm envious of the fact that I have been looking for a mad river explorer or malecite to salvage for like 4 months and then I come on here and read this post. Well I'm graduating college in 2 weeks and then maybe I can get a job and afford a canoe (even though I want a project, I'd much rather salvage one)... Oh wait the job market is terrible and I won't be able to find a job haha.

What did you use to fasten the gunnels Doc? I only see screws going into the deck plates. NICE JOB!

The other screws go from the inside.....look along that left inwale, you'll see them. The only outside screws are at the ends.

That woodwork and refinishing on the hull is amazing. What did you use to shape the wood, or did you buy the rails like that?

matt....we made the decks but ordered the gunwale kit from here

Thanks I have a lead on a canoe right now so that should be helpful. Wish me luck on getting it, she says its a mad river but she's not sure what kind (it was her sons). It is a garage sale too so I am hoping I can haggle a bit.

Wowsers Doc! Haven't been on in awhile to check up...looks like a beauty!

The woodwork and assembly is complete! I just have to take some things back apart, sand and Watco. Paddling will be soon!

well done!

Very nice job Doc. Got a weight on that baby?

not sure bum....after I finished it all, I put it up on my shoulders. It's light...I'd say 42ish. I'll weigh it when it's all done.

The Malecite came home today from the workshop. Just some minor details to finish up....spar urethane the cut ends of the seats, yoke and the seat hanger spacers. It will be assembled and finished on Saturday. I will try to post before and after pictures. It's been fun and rewarding. Hopefully there will be "Maiden Voyage" pics also. Thanks to all who gave advice.