Feathercraft K-Light Plus 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] Fax: [phone] www.Feathercraft.com [e-mail]
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
Feathercraft K-Light Plus 1

The K-Light Plus
Single Folding Kayak
Feathercraft K-Light Plus 2
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

Feathercraft K-Light Plus 3
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

Feathercraft K-Light Plus 4
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 hard-
ware 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 but-
tons 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 K-Light Plus 5

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.
Feathercraft K-Light Plus 6

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.
Feathercraft K-Light Plus 7

K-Light Plus Assembly Instructions
Feathercraft K-Light Plus 8
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 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 K-Light Plus 9

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.
5 STERN SECTION.
•Repeat Step #2 and #3.
Feathercraft K-Light Plus 10
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.
7INSERTING 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 K-Light Plus 11
Bow Stern

8INSTALL 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.
Feathercraft K-Light Plus 12
Delrin “twister”
Bow Stern

9EXPAND EXTENSION BAR.
•Lever keel extension using Stern Deck Bar/Vertical Lever
and Bow Deck Bar/Horizontal Lever. Expand until spring
button pops up.
10 INSTALLING 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.)
•Start with inserting a portion at the bow. Then insert a
portion 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.
Feathercraft K-Light Plus 13

11 INSTALL SEAT SLING.
•Stern end of seat sling has narrower stitching. Slide
Connecting Bars through loops in sling with oversleeve
tubes oriented towards the bow.
Feathercraft K-Light Plus 14
Bow Stern

12 INSTALL 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-con-
nector 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.
Feathercraft K-Light Plus 15
A
CD
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

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 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.
14 REPEAT STEP 13 FOR INSTALLATION OF STERN CROSSRIB.
•Procedure is the same, except for twister.
Feathercraft K-Light Plus 16
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”

15. 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.
Feathercraft K-Light Plus 17
B
A

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.
Feathercraft K-Light Plus 18

17 INSTALL 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.
Feathercraft K-Light Plus 19