Building a Big Canoe begins with an open mold process. First, the completed fiberglass canoe is extracted from the mold, and the mold is prepped for the next canoe. The inside of the mold is then sprayed with a gel coat, which must be followed by the first layer of resin and fiberglass cloth within 24 hours to ensure proper adhesion. Over time, three layers of fiberglass cloth and resin are applied, creating the canoe’s durable structure. Once the fiberglass layers are in place, the mold containing the newly formed canoe can be set aside until the next build is needed. Additional layers of cloth are applied to the central floor for added reinforcement before carefully extracting the finished canoe from the mold and preparing the mold for the next cycle.

With the fiberglass shell complete, the wooden components are installed, which takes around 50 hours. The gunwales are glued and clamped onto the canoe, followed by the addition of thwarts, seats, and flotation compartments at the bow and stern. These flotation areas are covered with plywood, then sealed with fiberglass cloth and resin. The top gunwale railing is attached, and four layers of oak are bent and glued to form the bow and stern gunwales. Once the woodworking is complete, three coats of varnish are applied to protect and enhance the wood. The exterior of the hull undergoes a two-step gel coat and fiber treatment to achieve its signature brown and black textured finish. Finally, the canoe is fitted to a custom built trailer.

All that’s left is carving out a set of paddles to complete the project!