> I have the frame of a Klepper folding kayak but I don't have the skin and
> buying a new one is $2000

> Does anyone have a suggestion on how to build one, materials, how to,
> source of materials etc.?

> All form of advise or info is welcome and greatly appreciated.

> Jorge volare21@cwix.com 415/928-2839

Kleppers have special clips for holding the skin on. I`d suggest you ignore these and modify the frame a bit to accomodate a simpler fabric cover.

When you assemble the Klepper you insert half of the frame into the skin, then insert the other half, and connect the two halves, stretching the skin as you do so. Since the skin is still a bit slack, there are inflatable internal sponsons which expand as they are inflated, stretching the skin tight. I'd suggest you ignore the way that Klepper does this. The simpler method is to assemble the complete frame and set that into a skin that is either laced or zipped closed (or both) The advantages of lacing are that you can draw the laces tighter as the skin ages and stretches, and the cost is slightly less than a heavy-duty zipper.

Many kayaks are covered with canvas or duck fabric which is then coated with marine paint. If you are not planning to use this as a collapsible boat this is a simple method. A painted canvas skin will not take much folding before cracks start to appear in the finish. If you went this route I'd suggest you store the skin by rolling it gently around the bag with the frame pieces so that it does not make the sharp bends the would occur if you tried stuffing it into its own pack. A fresh coat of paint each year and this should last a while. George Putz in his boat on canvas covered boats describes the process.

For a more `foldable' skin material look into Hypalon, neoprene, or PVC (PolyVinyl Chloride) coated fabrics. The modern fabric here is usually nylon, but you can use these coatings on duck or canvas, too.

George Dyson, author of the book on Baidarkas sells several thicknesses of nylon fabric as well as neoprene and hypalon liquid which you paint on (several coats) to waterproof things. The fabric is in the $5 to $20 a yard range (varies by thickness and width) and the rubber coatings are a bit over $50 a gallon. Plus shipping. Some of these coatings require special (expensive) handling.

You can buy fabric that is already coated with neoprene or hypalon from McMaster Carr. (www.mcmaster.com) Do a keyword search for `fabric neoprene` They also have the glue for sealing seams. I suppose you could use glue to join pieces, but the method I have heard of is to sew together the pieces, then cover the stitches with sealant and maybe glue a neat patch over the joint, too.

The same process goes for using fabric which is coated with PVC. Some advantages of the PVC fabrics ( also called vinyl coated fabrics): Bright colors (not just black or white), cost, availability, and some of them will shrink a bit if you warm them with a heat gun or hair dryer. Test this first, though. If you get a fabric that heat-shrinks you can remove wrinkles easily.

Sign shops that make vinyl banners can get you banner material. Use the thickest you can find. I think McMaster Carr has it, too.

With a lace-up skin you assemble the frame and set it on the skin material. Bring up the fabric to cover the decks. Allow enough fabric so that you can roll or fold it so that water can't get in -- similar to how you owuld close a watertight bag. Make the deck with a row of grommets on each side, and lace them up, just like you would lace up a shoe, but with the rolled seam in the place where the tongue on your shoe would be. By lacing tightly you get out the wrinkles and keep the extra material from unrolling. The laces serve as deck lines for holding spare paddle, similar to bungee cords on a desk, but not as stretchy.

Youll have to arrange how to secure the fabric to the cockpit: clamps, battens, clips, whatever it takes. You might consider putting a row of grommets in the fabric that extends over the edge of the cockpit, fold that down, and use rope to lace that in. You may need to secure a board to the frame in the cockpit area just so you'll have something to tie to.

Hope these ideas help.

Paul Jacobson