Since there's already a thread today on alternative building techniques, I thought this an appropriate time to display my
latest folding kayak as it's about as alternative as I can make it ! As much as I like all types of kayak building, there's
nothing I enjoy more than the challenge of building folding kayaks.

The design goals for the "Falco" (named after my Aprilia, not the bird) were quick assembly, light weight, and low cost. To that end,
the Falco prototype assembles in well under 5 minutes, weighs 24lbs (10.9kg), and costs less than $100.00US to build.

The kayak uses plywood side panels, sliding plywood connecting plates, PVC / Vinyl hinges for frame folding, and folding hinged
plywood cross sections. No expensive materials, including sponsons are required, keeping costs to a minimum.

The attached pic of the Falco show it assembled and folded in the shop in addition to it's PVC travel bag for airline, auto,
or motorcycle transport. Motorcycle travel is the reason I started building folding kayaks in the first place :wink:

When folded, the 2-part coaming, deck rigging, deck ridge, and deck hatches fold inside for quick assembly. The keel and seat
plate are stored inside also, though the take-apart 4 section keel gets assembled for use. The keel is straight with no bent
aluminum stem pieces so it slides easily into PVC sleeves at the stems, greatly simplifying assembly.

If needed ...Use the {BACK} key to return from the Links below....

http://www.yostwerks.com/FalcoFramePartsA.jpg - The main structure is comprised of 3ea per side X 48" X 8.5" X 3/16"
(122cm X 22cm X 5mm) plywood side panels that use PVC hinges for folding. The side panels are connected together with
sliding plates that are 15" X 6" X 3/16 (38cm X 15cm X 5mm) plywood. These stiffen and strengthen the frame,
and slide apart allowing the kayak to fold via the PVC hinges.

The plywood panels are covered with PVC as this makes a base for attaching the PVC hinges for folding and also the PVC hinges
and Velcro for the cross sections. Plus, it gives the boat a true SOF appearance. All wood, including the plywood side panels
is sealed with HH-66 vinyl cement. Frame pics were taken before adding the deck so that the construction and assembly techniques
could be seen.

http://www.yostwerks.com/FalcoDeckridge4A.jpg - Deckridge and frame details. The 4 folding 1/2" (12.7mm) cross sections
are hinged on one side with PVC and connect on the opposite side with Velcro. The cross sections simply fold over inside
the hull which makes assembly / breakdown very easy. The plywood cross sections attach to the keel with HDPE snaps.
The front deckridge is wood and it also folds for assembly.

http://www.yostwerks.com/AssyC.jpg - Folding sequence .... before the deck was attached.

http://www.yostwerks.com/PVCKeelSleeve2.jpg - The keel is 3/4" (19mm) aluminum tubing as it's the easiest method of making
a stringer that disassembles, though wood can be used also. The front and back of the keel tube slide into a PVC sleeve during
assembly and the 4 keel sections stay inside the boat when disassembled. The hull bottom and deck are PVC skinned.

http://www.yostwerks.com/FalcoDryBagAll.jpg - Roll-Up dry bag style deck hatches. The deck is PVC skinned and uses clear vinyl drybag
style hatches for storage as well as providing "visual" access to cross sections 1 and 4 for assembly. The clear vinyl used for the hatches
provides more light for assembly. The rolled-up hatches secure to the deck with Velcro, though plastic buckles can also be used.

http://www.yostwerks.com/FalcoCoamingAll.jpg - The breakdown coaming is made of 1/2" (12.7mm) aluminum tubing that connects at the
center with 3/8" (9.5mm) inserts. The coaming is covered with PVC . It folds into the skin during disassembly. By folding with the skin,
no time is lost during assembly.

http://www.yostwerks.com/FalcoRiggingAll.jpg - The deck rigging uses glued PVC tabs and D-Rings to secure the elastic cord. The rigging
folds with the skin for assembly.

http://www.yostwerks.com/FalcoSeatA.jpg - Plywood / PVC seat plate. The seat plate is 3/16" (5mm) plywood, same as the side panels
and sliding plates. The seat snaps under the bottom of the plywood panels (chine) and is reinforced with PVC strips along the edges for
durability in the chine area. An inflatable cushion, foam or hard seat can be added, or the seat plate can serve as the seat alone.

http://www.yostwerks.com/FalcoBagAll.jpg - PVC travel bag. In addition to the kayak, it also holds 2 breakdown GP paddles.

http://www.yostwerks.com/Falco16All.jpg - Here's a drawing of the next Falco. It too will have 5mm plywood side panels, 12mm plywood cross sections,
aluminum keel, 12.7mm aluminum coaming, and a PVC skin and hinges. Cost should be about $125.00US with assembly less than 5 minutes.

The Falco 16 is a shorter / wider version of the Sea Rider, but I may make additional design changes before starting construction. The third boat in this series
will be a small double that can be paddled also as a high volume touring single.

The Falco folding kayak is as easy and as inexpensive to build as my non folding wood frame SOF kayaks ... and that's something I would never
have thought possible for a folder. I'll post offsets and detailed building instructions after on water testing ... as soon as the ice melts.

Simple is as simple does :mrgreen:

Regards, Tom