KERO PakCanoe User Manual

end cap

Pakboats PakCanoe

Assembly Instructions

Note: Please read these assembly instructions carefully before assembling the canoe.

air tube

gunwale rod

cross rib

gunwale
terminator

stem

air tube
support rod

canoe skin

gunwale

channel

keel rod

latch rod

chine rod

Installing air tubes

The first time a new canoe is assembled, the air tubes need to be installed. Roll out the canoe skin an d the air tubes. The two
air tubes will have to be separated by peeling them from each other. Along the edges of the canoe skin, you will find a channel
with holes facing the inside of the canoe. There are corresponding holes along one side of each air tube. You will use the short
plastic ties found within the repair kit to connect the air tubes permanently to the canoe skin. When you are done, the tubes
should fit against the inside of the canoe skin on each side.

1. Place an air tube against the inside of the canoe skin with the valves facing into the canoe and the wide edge with punched
holes next to the canoe skin's gunwale channel.

2. Insert a plastic tie into the small hole closest to the end of the gunwale channel and out through the larger hole. Feed the tie
through the corresponding hole in the edge of the air tube. Close the tie and leave about a 2" free end. Cut off the end.

3. Repeat the procedure for all the holes along the side of the canoe.

4. Install the air tube on the opposite side the same way.

Assembling the canoe

Note: Don't be afraid to get into the canoe while you are putting it together. Most of the assembly is much easier if
you are inside the canoe.

1. Unpack the canoe and put like color coded parts together. Assemble the straight (shock corded) rods. Put aside the two rods
with the black plastic end caps (you will need them when you get to step #10). Place the straight rods next to each other, lining
up one end so the rods can be sorted by length.

2. The two longest rods are gunwales (identified by the red sticker). Starting from one end, insert a gunwale into a sleeve in the
canoe skin (along the top on each side). It helps to fold the tip of the skin out of the way and make the gunwale channel as
straight as possible. Repeat the process with the other gunwale rod.

3. Locate two small horseshoe shaped parts marked with a red sticker. These are

"gunwale terminators". Insert one end of a gunwale terminator into the end of a
gunwale. Put the other end into the other gunwale (it will barely go in at all). See Fig

2. Spread the gunwales apart until the tube end aligns with the gunwale terminator,
slip the terminator into place (make sure it is all the way in). You may find it is
simplest to align the gunwales by pushing them apart with your thighs from inside
the canoe. Pull the canoe skin up around the gunwale terminator. The gunwale
terminator must be centered between the gunwale channels. If this does not happen,
the assembled canoe may be warped and the end caps will not fit properly. Repeat
the process at the other end of the canoe.

Note: Both gunwale ends must be inside the canoe skin before you go on to step 4.

4. The shortest straight rod is the keel. The curved parts with metal forks are stems. Place the keel in the canoe. Insert the

narrow end of one stem into the keel rod end. Lift the gunwales and clip the center of the gunwale terminator onto the top of
the stem. Repeat the process with the other stem at the other end of the canoe.

Note: You must have the gunwale terminators in place on top of the stems before proceeding to the next step.

5. The two longest remaining rods are chine rods identified by yellow stickers. The ends of the chine rods fit onto the forks

(also marked with yellow stickers) attached to the stems nearest each end of the canoe (the fork prongs fit into the ends of the
rods). With the rod attached at one end, make the rod form an even arc and attach to the corresponding fork at the other end.
Push the center of the rod down and to the side so it rests inside the canoe skin. Repeat the process with the other rod of the
same length. Repeat step 5 with the latch rods identified by the blue sticker fitting onto the forks designated by the blue sticker.
Make sure the latches at the center of the latch rods point in the same direction on both rods. The latches should be on top of
the rod.

Note: When the longitudinal rods are installed, the stems are pushed into the ends of the canoe skin, exposing the
narrow sections that were inserted into the keel. If the joints of the keel rod start separating, pull the keel rod away
from the stems enough to close the keel joints.

6. Inflate the air tubes by mouth (this gives the right amount of pressure to help assembly).

7. Lay out the cross ribs next to the canoe with the narrow ones closest to the ends and the widest ones at the center.

Installation will begin with the widest cross rib at the center of the canoe.

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