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Standard Gear

Diagram from the Feathercraft manual, but it seems to be missing the cockpit coaming...

Additional gear, some customised

For deck from bow: Painter, Two hatch covers, Net bag, Map case bungy, Seat and two cushions, Spraydeck, Rudder prussick, 2 Teva holders, Paddles, Paddle holders (bungies, red strap and binos), Flags, Rudder (with two D-clips).

Two deck raising beams with cord.

Rudder and cables, footrest assembly (main piece, two side pieces, butterfly nuts, two D-clips).

Assembly

These assembly instructions are from the Feathercraft manual modified for my customisations.

1 - Make up the ends and insert in skin

Add the deck-raiser beams to bow section

2 - Install and expand keel extension bar

Wrap Velcro closure around tube. Attach Keel bar to bow and stern section Keel bars. Lever extension bar using Stern Deck Bar/ Vertical Lever and Bow Deck Bar/Horizontal Lever. Expand until spring button pops up in first hole. An additional "pusher" block has been installed on the bow keel bar. If the bow and stern sections need to be separated further to insert the keel bar, push against this block using the lever bars.

3 - Install starboard (blue) and port (yellow) chine extension bars.

Expand chine extension bars to first hole, then expand keel extension bar again

4 - Install seat sling and gunwale extension bars

Stern end of seat sling has narrower stitching. Slide Port and Starboard Gunwale Extension Bars through loops in sling.

Attach side pouches. Counter intuitively, the wider end goes towards the bow!

Attach Gunwale Extension Bars to frame and expand to first hole. Slide lower flaps of seat sling under Chine Bars. (Do not attach Velcro until #3 and #4 Crossribs are in place).

At this point ensure that the entire frame is straight. Look down the entire kayak. You may have to rotate the bow or stern end slightly. During additional assembly steps, keep re-checking that the frame has remained centred in the skin.

5 - Install #3 and #4 crossribs

Place Crossrib directly above the keel and chine bars and push down. Tilt the Crossrib back towards the Stern and engage the two Gunwale bars. Straighten the crossrib and slide forward/backward until it is near the spring buttons that protrude from the keel and chine extension bars. Ensure that rudder cables are outside of all ribs.

6 - Install bow reinforcement bar/horizontal lever

7 - Install bow and stern cockpit reinforcement bars and connect them

Remember to slide through seat strap and side pouches through

8 - Attach web loops to #4 crossrib

On the inside of the deck behind the #4 crossrib are pieces of webbing. Install over crosspiece as shown, and then back through the slot in the crosspiece. Secure to ladderlock buckle.

9 - Install stern deck bar/vertical lever

Cinch web loops (#20) to hold firmly in place.

10 - Finish off

Cockpit coaming, hatch coamings and covers, rudder, footrest and straps.

Go home time (sniff!)

Based on packing into a Mountaincraft large bag, as the Feathercraft pack is alas far too heavy and cumbersome for lightweight expeditioning...

Place seat saddle on base of bag for extra strength, and some cardboard or whatever else you can scrounge.
Put the seat cushion in the bag first, with the cushion facing down, to give padding for your back.
Stretch the sprayskirt over the fibreglass coaming. Place this in the bag, over the crossribs.
Roll the kayak skin up tightly�fold the ends to the center of the kayak; fold in half; roll tightly; secure with webbing ties.

: Pull out the hoses attached to the sponsons and open the`valves. Remove hatch rims. Fold the bow and stern ends towards the middle of the skin. Fold half of the skin over onto the other half, lenghtways. Roll up the skin toward the mid point where the sponson hoses are located. This will ensure that air in the sponsons is forced out. Close the valves on the sponson hoses and tie the skin. Roll up tight and snug.

Put the bow frame parts on one side of the bag, and the stern parts on the other.
Place the folded skin between the frame parts.
All the remaining tube frame parts are then placed over the bow and stern section bundles.
Next arrange the white plastic crossribs and hatch rims over the seat.

Repair

The Polytech deck and Duratek hull are urethane. Seams are permanently sealed. A patch kit is provided for deck, hull or sponson punctures. A urethane adhesive such as Aquaseal will work for repairs to all of these fabrics. Glue does have a shelf life and it should be fluid and not thick and gummy.

The HDPE cross-ribs can be affected after extended use in the heat of the tropics. They may seem to warp to a small degree and want to curve with the shape of the boat. They can easily be "shaped" flat again by heating them (laying them in the sun).