Feathercraft Kahuna, Big Kahuna User Manual

THE LEGENDARY PERFORMANCE OF

YOUR ADVENTURE UNFOLDS

Feathercraft Products Ltd. 4-1244 Cartwright Street on Granville Island, Vancouver, British Columbia, Canada V6H 3R8

Telephone: [phone] Toll Free: 1-888-681-8437 Fax: [phone] www.Feathercraft.com [e-mail]

2006 Kahuna &

Big Kahuna

with built-in coaming

FOLDING KAYAKS

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Contents

Kahuna Folding Kayak...........................................................Page 2

Specifications ........................................................................Page 3

Kahuna Frame .......................................................................Page 4

Care and Maintenance ..........................................................Page 5

Kahuna Assembly Instructions ..............................................Page 7

The Feathercraft Sea Sock......................................................Page 21

Disassembly ..........................................................................Page 22

Optional Rudder Installation .................................................Page 23

Optional Hatch Installation ...................................................Page 26

Feathercraft

Kahuna

1

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The Kahuna
Single Folding Kayak

Feathercraft

Kahuna

2

Bow Loop

Built in Coaming

Comfortable Sling Seat

Stern Loop

Ability to install optional

Surf Rudder

End Reinforcement

Removeable air sponsons inside
skin along gunwales

Hull reinforced on outside over
Keel and Chine Bars

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Feathercraft

Kahuna

3

Seat: 1/2" closed cell foam back & bottom,

contoured plastic seat bottom,
3/16" plastic seat back with inflatable
lumbar support, inside a 420 denier nylon
seat cover.

Accessories: Included in every kayak:

Nylon Spray Skirt
Sea Sock
Adjustable Foot Braces/Rudder Controls
Repair Kit
Pack Bag
Assembly Video
Illustrated Instructions

Options: Access hatches

Surf rudder
Neo-nylon spray skirt
Calf plates

Specifications

Length: 4.5 m (14'9")
Beam: 64 cm (25")
Weight: 16 kg (35 lbs)
Pack size: 90 x 50 x 25 cm (36 x 20 x 10")
Storage Volume: Medium
Frame: 5/8" Round

6063 - T832 Extruded Aluminum
Magnesium Tubing with clear

Anodized Coating
Crossribs: Injected Molded Polycarbonate
Deck Material: Polytech
Hull Material: Duratek

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Feathercraft

Kahuna

4

Kahuna Frame

stern deck bar/lever bar

chines, gunwales and deckbars

through-bolted permanently

to injection-molded

polypropylene keel plate

(same for bow and stern)

crossribs are injection-molded

polycarbonate

5 extension bars: chines, gunwales, keel

adjustable foot braces

shockcorded tubing

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Care and Maintenance

The Frame.

The tubular frame is very strong and corrosion resistant. We
recommend that the frame be disassembled after extensive use
(2 – 3 months). The inside and outside of the tubes should be
washed with fresh water. Try to keep the inserts and extension
bars free of sand and grit.

Included in your repair kit is a small dropper tube of Bo-Shield T-9.
This product is made by Boeing and is an excellent lubricant
and protectant for aluminum.

Aerosal containers of Bo-Shield can be found at marine hard­ware stores. We also have available 4 oz bottles of Bo-Shield.
However, please note, that the lid closure is not suitable for
shipping after the bottle has been opened. This container
would be good for your “at home” clean-up. We also have
available Super Lube. This is a teflon lubricant in gel form. This
product is also available from bike shops.

Apply the Bo-Shield lubricant to frame tube inserts, spring but­tons and sliding pieces prior to assembly. If you should leave
your boat assembled for a maximum of two months, this will
assist in preventing tubes seizing.

Other maintenance “musts”:

• every two months completely disassemble the kayak.

• wash the frame completely with fresh water.

• reapply lubricant and/or wipe down tubes with Bo-Shield T-9.

• after paddling, sponge out the inside of the kayak.
Do not allow water to pool along keel bar.

The Skin

The surfaces of the skin will not rot. They are stable in sunlight and
are very tear-resistant. On the hull, areas likely to be exposed
to abrasion have been reinforced. However, we recommend
care when approaching shore. Sharp rocks, and barnacles can
penetrate the skin. Never haul the boat over rocks.

For patching and repairs, a patch kit is included. For quick field
repair, duct tape works very well, and is a good addition to
your repair kit.

Feathercraft

Kahuna

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Welded Sealskin.

The Polytech deck and Duratek hull are urethane. Seams are
permanently sealed.

A patch kit is provided for deck, hull or sponson punctures.
One urethane glue 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. We have replacement cans available.

Sponsons

Due to the tight fit of the skin, the sponsons are under
considerable pressure and some seepage of air may occur. It is
advisable to periodically reinflate the sponsons. After paddling
on hot days, release air from sponsons.

To Repair/Replace Sponson

The sponsons can be completely removed from the sleeve
sewn to the inside of the skin. Turn the skin inside out. The
sponson chamber is open at bow and stern ends. Tie a long
string through the hole in the tab at the end of sponson. Pull
sponson through the center opening of the chamber (where
sponson hose is attached). To reinstall, pull the cord attached to
the new sponson back through the chamber. Ensure sponson is
not twisted in the chamber. Repeat with the opposite side.
Urethane glue and patches are included in the repair kit. Duct
tape works well on the sponsons.

Lifting the Kayak

The webbing handles at the bow and stern ends can be used
to lift or carry. Never lift or carry a fully loaded kayak.

Feathercraft

Kahuna

6

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Kahuna Assembly Instructions

Feathercraft

Kahuna

7

Seat

Bow Section

Chine and Gunwale Extension Bars

Keel Extension Bar

(has double band of black tape at stern)

Skin

Crossribs

Rim Inserts

Thigh Braces

Stern Crossrib–marked with “S”

Bow Deck Bar/Horizontal Lever
Stern Deck Bar/Vertical Lever

Seat Sling

Bow deck bar is slightly bent

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1 SET OUT FRAME PARTS AS ILLUSTRATED ON THE PREVIOUS PAGE

2 BOW SECTION

(has foot track installed on chine bars).

• “Shake out” bow section. Shock corded tubes take shape.

Feathercraft

Kahuna

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3 ATTACH SMALL CROSSRIB TO BOW SECTION.

• Pin on small crossrib is inserted into hole in plastic block on

keel tube; fit into place.

• Snap chine and gunwale tubes on to crossrib.

When the crossrib is in position, the white spacers are on
the “cockpit” side of the crossrib.

4 COMPLETE BOW SECTION.

• Slide foot braces on to track. If necessary, the foot plate on

the brace can be reversed.

5 STERN SECTION.

• Repeat Step #2 and #3.

6 UNFOLD SKIN.

• There are two Velcro-tab

closures on the inside of the
hull. These are located through
the main cockpit opening,
bow and stern.

Feathercraft

Kahuna

9

White spacers

Bow Frame Section

Note: Bow deck bar
has slight bend

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7 INSERTING FRAME SECTIONS TO SKIN.

• Before inserting the frame into the skin, ensure the velcro

tabs are open. Slide the bow and stern frame sections into
the skin. (Feathercraft label is on the bow end.)

• When inserting the frame sections, align and centre the

frame using the tabs as guides. Snug the frame sections to
the very tip of the skin.Secure Velcro closure around the
keel bar.

Feathercraft

Kahuna

10

Bow Stern

Stern Frame Section

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8 INSTALL KEEL EXTENSION BAR.

• Keel extension bar has two bands of black tape on the

stern end, and one band of black tape on the bow end.

• Slide the stern end of the extension bar on to the stern

keel bar. Slide the bar apart, attaching the other end to the
bow keel bar.

Feathercraft

Kahuna

11

Delrin “twister”

Bow

Stern

Single band of black tape

Double band of black
tape towards stern

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9 EXPAND KEEL EXTENSION BAR.

• Lever keel extension using Stern Deck Bar/Vertical Lever
and Bow Deck Bar/Horizontal Lever. Expand until spring
button pops up.

Please note: Due to the nature of the skin fabrication, there can be minor
“fit” differences from one boat to another. We have made seven positions
for the keel bar extension to allow for these differences in expanding the
frame to the skin. Expand the keel bar to the hole that feels tight.
(Usually, this will be the middle or second last hole.)

10 INSTALL RIM INSERTS

Bow

Stern

Stern

Rim Insert

Slide into pocket on underside
of coaming rim

Feathercraft

Kahuna

12

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11 INSTALL SEAT SLING.

• The seat sling will be suspended from the chine and gun­wale extension bars. These extension bars are all the same.
Stern end of seat sling has narrower stitching. While
installing and expanding these extension bars, you may
wish to slide the seat sling over the chine and gunwale
bars on the stern section of the frame. Otherwise, slide
Extension Bars through loops in sling with the black delrin
blocks oriented towards the bow.

Feathercraft

Kahuna

13

Bow Stern

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12

• Install chine and gunwale extension bars.

• Once the bow and stern frame sections have been inserted
to the skin, they begin to take the curved shape of the
kayak. It will be easier to slide tubes together when the
tubes are in a straight line to each other.

• The black Delrin block on the extension bars points to the
bow. Slide the bars open, and join to the bow and stern
sections.

• Expand the chine bars as you did the keel bar, till the
spring button appears in the first hole.

• Expand the gunwale bars to the first hole.

• Go back, and expand the keel to the second hole.

• Expand chine and gunwales to the second hole.

• Slide the seat sling forward for seat positioning.

Feathercraft

Kahuna

14

Note: When installing
frame parts in the
kayak, it is easier to be
situated on the opposite
side from the part you
are installing.

Bow

Stern

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13 INSTALLING LARGE CROSSRIBS.

• Position large crossrib to lay on top of gunwale tubes.
Slide forward towards pins on gunwale tubes. Rotate
crossrib into position.

• Place crossrib between gunwale pins nearest you by push­ing gunwale bar up over end of crosspiece and snapping
into position.

FOR BOW CROSSRIB:

• There are two black plastic blocks mounted on the keel
bar. One is mounted with a screw and can be rotated.
When rotated away from the other block, it is in the
“open” position. Have the block set in the “open” position.

• Insert pin located on bottom of crossrib into stationery
black block on keel bar. Twist the second block into the
“closed” position. Snap crosspiece into position on
gunwales, then chines.

Feathercraft

Kahuna

15

A

B

Note: This step is done when frame is in the skin.
For illustration purposes, we have shown it without the skin.

Delrin “twister”

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Feathercraft

Kahuna

16

14 REPEAT STEP 13 FOR INSTALLATION OF STERN CROSSRIB.

• Procedure is the same, except for twister.

15 SECURE DECK-WEBBING TO CROSSRIB.

• Attached to the underside of the deck, behind the large
stern crossrib, are pieces of webbing with buckles.

• Clip to the corresponding buckle attached to the crossribs.

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Feathercraft

Kahuna

17

16 INSTALL BOW DECK BAR.

• Insert through small hole in top of large crossrib.

• Join to shockcorded deck bar.

• Hold through deck.

• Turn to lock into place.

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17 INSTALL STERN DECK BAR.

• The stern deck bar has the same spring-button
adjustments as the stern frame section. Have the spring
button position on the deck bar at the same position as
the rest of the stern section.

• Put the stern deck bar through the center of the large
crossrib: end with black block pointing towards the stern.

• Bring deck bar end closest to you, back through small hole
in top of crossrib.

• Line up bar, and insert to shockcorded deck bar. Hold the
shockcorded deck bar through the deck while turning the
deck bar to lock into place (as you did in Step #15).

• Ensure spacers on the deck bar do not face upward, push­ing against inside of the deck.

Feathercraft

Kahuna

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18 INSTALL THIGH BRACES.

Slide oversleeve on thigh brace towards bow.
Insert stern end of tube (a) through hole in large stern
crossrib. Insert bow end (b) through hole in largebow
crossrib. Slide oversleeve towards stern till spring button
appears in 2nd hole.

Feathercraft

Kahuna

19

Gunwale Bar
Thigh Brace

pull tightly

ba

Thigh brace is secured with web strap.

Thigh Brace Bow has white spacer.

Stern has oversleeve.

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19 INSTALLING SEAT.

• Webbing at top of seat goes through crossrib, over top,
connecting to buckle.

• Webbing at front of seat reaches the large crossrib and
attaches around the side of the crossrib. Connect to
ladderlock to fasten.

• Note: Webbing goes above chine bar.

20 INFLATE SPONSONS.

• Turn the top of the valve to open. When inflating sponsons,
alternate sides to ensure the frame remains centered. The air
pressure from the sponsons can shift the frame within the
skin. Keep blowing until the skin is nice and tight. Twist
top cap to close. Tuck sponson tubes and valves out of the
cockpit area. Avoid stepping on the hose and valve, and
try to keep the valve free of sand.

Feathercraft

Kahuna

20

A

B

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Feathercraft

Kahuna

21

The Feathercraft Sea Sock

Made from high-quality coated nylon, the sea sock is a great
safety item. The top of the sock fits tightly around the cockpit
coaming rim. Contoured to fit along the seatback and bottom,
the “foot” is loose through the cockpit, creating a “pod”. The
paddler then sits in the sock. Legs and feet are not constricted.
The spray skirt fits as usual. In the event of a capsize, water will
only enter the sock, and not the whole boat. It’s also great
for keeping the inside of your kayak clean.

As an optional upgrade, the Sea Sock can be ordered with a
neoprene rim-grip. This gives an extra tight fit for paddling in
extreme weather conditions.

Tips on Usage and Installation

• The shiny side of the fabric faces in towards the
kayak frame.

• When facing the bow of the kayak, the Feathercraft label
should be on the right side.

• The center seam on the up-side of the Sea Sock should be
centered on the bow point of the coaming.

• Once the Sea Sock is in place, sit in the sock, and “burp”
it by lifting the edges, releasing trapped air that causes the
sock to billow up.

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Disassembly

Let the air out of the sponsons. Remove rim inserts. Remove
deck bars. Remove Gunwale and Chine Extension bars using
the lever bars to release the spring buttons. Release the Keel
Extension Bar last. Follow the rest of the assembly steps in
reverse order.

Packing the kayak in the bag

Put the seat cushion in the bag first, with the cushion
facing down, to give padding for your back. Next arrange
the white plastic crossribs over the seat. Roll the kayak skin
up tightly–fold the ends to the center of the kayak; fold in
half; roll tightly; secure with webbing ties. Place this bundle
in one side of the bag. Put aluminum frame parts along side
of the rolled up skin. Tuck all additional pieces (ie: sea sock,
repair kit) into any available space.

Storage

Once clean and dry, the kayak can be stored assembled or
disassembled in a shaded, dry place. When storing the kayak
disassembled, take extension bars apart.

Feathercraft

Kahuna

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Installation of Optional Accessories

TO INSTALL THE OPTIONAL SURF RUDDER

• The rudder casting is permanently attached to the stern of
the kayak.

• Insert the rudder pin through the “key hole”.
Rotate rudder 180º.

• Attach rudder cables with sister clips. White haulcord is
attached to clip at the side of the cockpit.

Feathercraft

Kahuna

23

Sister Clips (two of these
clips are mounted on each
side of the rudder).

A

B

C

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A CONNECTING RUDDER CONTROL TO FOOT BRACE

• Red webbing adjusters are connected to the foot brace.
Unscrew thumb-knob on foot brace; stem of knob goes
through grommet. To make the adjuster shorter, fold
webbing over to second grommet. Re-attach knob to foot
brace. Slide brace on to track. Ensure brace can slide easily
on track. (If not, check knob that you re-attached.)

Feathercraft

Kahuna

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Grommet

Fold over to shorten

Thumb screw knob

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B CONNECT CABLE ADJUSTER TO STAINLESS STEEL CABLE.

• This is to attach the adjuster if you have installed the
rudder from a kit.

• Slide end of webbing through slider buckle. Thread the
webbing through the loop in the stainless steel rudder
cable. Fold or “pinch” webbing to make a V. Re-thread
webbing through slider buckle.

C CABLE LENGTH ADJUSTMENT

• To shorten cable length, pull on tab of webbing with loop;
to lengthen, lift tab of ladder-lock buckle.

Feathercraft

Kahuna

25

Slider buckle

Fold webbing to
make a V

Ladder-lock buckle

Tab with loop

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To install optional hatches

ATTACH HATCH RIMS.

• Attach hatch rims by folding the fabric sleeves sewn to
the deck over the rim. Roll down inner closure and
close with buckels. Place hatch cover over rim and secure
with B-locks.

• During disassembly, don’t forget to take the plastic rims
off. Don’t roll the skin up with the rims still in place.

Feathercraft

Kahuna

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© Feathercraft Products Limited 2001
Printed in Canada, revised 7/2006
Recycled paper

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