Feathercraft K-Light Plus Instruction 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] Fax: [phone] www.Feathercraft.com info@ feathercraft.com

K-Light Plus

TM

FOLDING KAYAKS

Contents

K-Light Plus Single Folding Kayak.........................................Page 2

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

K-Light Plus Frame................................................................Page 4

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

Disassembly ..........................................................................Page 6

K-Light Plus Assembly Instructions.......................................Page 8

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

Optional Rudder Installation.................................................Page 22

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

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The K-Light Plus
Single Folding Kayak

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Bow Loop Fibreglass Coaming Comfortable Sling Seat

Stern Loop

Ability to install optional
Surf Rudder

End Reinforcement

Removeable air sponsons
inside skin along gunwales

Loops for attaching
cargo lines

Hull reinforced on outside over
Keel and Chine Bars

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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
Deck-lines

Specifications

Length: 3.9 m (12'10")
Beam at Cockpit: 64 cm (25")
Weight: 14.5 kg (32 lbs)
Pack size: 89 x 50 x 25 cm (35 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 or Coated Cordura Nylon,

1000 Denier, 11 oz.
Hull Material: Duratek

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Crossribs and Keel Plates injection molded plastic

Fibreglass coaming

Stern Deck Bar/Lever Bar

Chines, Gunwales and Deck
Bars Through-bolted
Permanently to Keel Plate
(For both Bow and Stern)

Keel Extension Bar

Shockcorded Tubing

Chine and Gunwale
Connector Bars with
Oversleeves

Adjustable Foot Braces

K-Light Plus Frame

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 h a rd­w a re 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.

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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.

Sewn Nylon Cordura Deck.

Over time, the skin may loosen when wet, and contract when
dry. If the skin is too tight when you assemble the kayak,
thoroughly wet the skin before stretching the frame.

If you notice seepage through seams, you may wish to seam-seal
the skin. The repair glue can also be used as a seam sealer. The
deck to hull seam and the top deck sponson seam are sealed
from the outside. Other deck seams, turn the skin inside out,
and seal from the inside.

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.

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Disassembly

Let the air out of the sponsons. Remove Cockpit Coaming.
Remove Gunwale and Chine Connector bars. Install Stern Deck
Bar into Keel Extension Bar. Take up tension with the Lever in
order to remove the Keel Extension Bar. 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. 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. 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.

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.

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 bar apart.

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K-Light Plus Assembly Instructions

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Seat

Bow Section

Connecting Bars

Keel Extension Bar

Skin

Crossribs

One-piece fibreglass coaming

Stern Crossrib–marked with “S”

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

Seat Sling

1 SET OUT FRAME PA RTS AS ILLUSTRATED ON THE PREVIOUS PA G E

2 BOW SECTION

(has foot track installed on chine bars).

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

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3 AT TACH 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.

5 STERN SECTION.

• Repeat Step #2 and #3.

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White spacers

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.

7 I N S E RTING 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.

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Bow Stern

8 I N S TALL KEEL EXTENSION BAR.

• 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.

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Delrin “twister”

Bow Stern

9 E X PAND EXTENSION BAR.

• Lever keel extension using Stern Deck Bar/Vertical Lever

and Bow Deck Bar/Horizontal Lever. Expand until spring
button pops up.

1 0 I N S TALLING FIBREGLASS COAMING.

• Place fibreglass coaming over cockpit opening. A thin

piece of rubber is sewn into the skin around the cockpit
opening. This edge is brought through the cockpit
opening, and tucked into the groove in the fibreglass
coaming. (It is a snug fit.)

• S t a rt with inserting a portion at the bow. Then insert a

p o rt i o n at the stern. Complete with inserting the sides.

• Note: if the deck has become tight, the coaming can also

be installed after the bow crossrib is in place.

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1 1 I N S TALL SEAT SLI NG.

• Stern end of seat sling has narrower stitching. Slide

Connecting Bars through loops in sling with oversleeve
tubes oriented towards the bow.

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Bow Stern

1 2 I N S TALL MID-CONNECTORS.

• 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.

• When beginning to install the mid-connectors, pull the

stern chine bar towards the center of the kayak. Slide on
stern end of mid-connector. Pull bow section of
mid-connector forward, extending shockcord. Mid-con­nector tubes will be “overlapped”. Pull bow chine tube to
center of skin to bring in line to mid-connector. Slide bow
end of mid-connector on to chine bar.

• With both ends of the mid-connector now attached to the

chine tubes, push the mid-connector “out” towards the
outside of the skin. When the mid-connector tubes are in
line, pull back towards the center of the skin, and slide
sleeve over join.

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A

C

D

B

Pull tubes “in-line”
to each other to
slide easier.

Shockcord is extended.
Tubes are “overlapped”.

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

Bring mid-connector
tubes “together”.

Oversleeve

1 3 I N S TALLING LARGE C ROSSRIBS.

• 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 push-

ing 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.

1 4 R E P E AT STEP 13 FOR INSTA L L ATION OF STERN CROSSRIB.

• Procedure is the same, except for twister.

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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”

1 5 . SECURE DECK TO CROSSRIBS.

• On the underside of the deck behind the large crossribs

are pieces of webbing.

• Install over crosspiece as shown, and then back through

the slot in the crosspiece.

• Secure to ladderlock buckle. (As shown.) This is the same

for both bow and stern large crossribs.

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B

A

1 6 I N S TALL 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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1 7 I N S TALL STERN DECK BAR.

• 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, push-

ing against inside of the deck.

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1 8 I N S TALLING 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.

1 9 I N F L ATE SPONSONS.

• Tu rn the top of the valve to open. When inflating sponsons,

a l t e rnate sides to ensure the frame remains centere d . 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.

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A

B

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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.

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.

Installation of Optional Accessories

TO INSTALL THE OPTIONAL SURF RUDDER

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

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I N S TALL RUDDER.

• 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.

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

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.)

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Grommet

Fold over to shorten

Thumb screw knob

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.

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Slider buckle

Fold webbing to
make a V

Ladder-lock buckle

Tab with loop

To install optional hatches

AT TACH 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.

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© Feathercraft Products Limited 1998
Printed in Canada 01.2000
Recycled paper