Feathercraft K2 Expedition Double 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]
K2 Expedition Double
with built-in coamings
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Contents
The K2 Expedition Folding Kayak..........................................Page 2
Specifications ........................................................................Page 3
K2 Frame ...............................................................................Page 4
Care and Maintenance ..........................................................Page 5
Disassembly ..........................................................................Page 6
K2 Assembly Instructions ......................................................Page 7
Feathercraft K2 Expedition Double 1
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The K2 Expedition Double
Folding Kayak
Feathercraft Folding Kayaks are the culmination of many years
of design development and testing. The Feathercraft K2 is a
stable, high volume, ocean touring kayak that
performs exceptionally well in rough conditions.
Feathercraft K2 Expedition Double 2
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Feathercraft K2 Expedition Double 3
Seats: 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.
Sponsons: Welded Urethane, with hose and valve
Standard Accessories:Deck-lines and rigging
Large fin flip-up surf rudder
Adjustable foot rests and seat slings
2 nylon spray skirts
2 sea socks
Large duffel-style pack-bag, with
shoulder straps & hip-belt
Packcloth over-the-shoulder carrying bag
Repair kit
Assembly video
Specifications
Length: 6 m (20')
Beam: 85 cm (33")
Pack size: 112 cm x 58 cm x 36 cm (44 x 23 x 14")
Weight: 39 kg (87 lbs)
Frame:
Main Members: 5/8" O.D. square & 3/4" round 6061-T6
aluminum alloy
Crossribs: High density polyethylene
Rivets and Spacers: Aluminum and Nylon
Screws and Bolts: Stainless Steel
Protective Coating: Clear Anodized
Deck: Polytech
Hull: Duratek
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Feathercraft K2 Expedition Double 4
Crossribs handcrafted from
High Density Polyethylene
Pieces are Colour-coded
Tubing is Shockcorded
Adjustable foot braces
Keel plate stiffener bar
Chine tubes with oversleeves
Mast attachment Hinged gunwale
Chines, gunwales and deck bars permanently
through-bolted to HDPE* keel plate
(similar for both bow and stern)
Gunwale lock
Frame stiffener plates on keel and gunwale
K2 Frame
Hinged keel
*High Density Polyethylene
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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 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. Areas likely to be exposed to abra-
sion have been reinforced. However, we recommend care when
approaching shore. Sharp rocks and barnacles can penetrate
the skin. Never haul the boat over rocks.
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. For quick
field repairs, duct tape works very well and is a good addition
to your repair kit.
Feathercraft K2 Expedition Double 5
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Tie-Downs
Webbing straps across the stern will secure a spare paddle.
Shockcord in front of the cockpit is handy for holding a chart.
Loops which secure the perimeter line can be used for lashing
additional gear to the deck.
Sponsons
Due to the tight fit of the skin, the sponsons are under consid-
erable pressure and some seepage of air may occur. It is advis-
able 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.
Disassembly
Let the air out of the sponsons. Remove cockpit rim inserts,
rebars and hatch rims. Remove seats and seat slings. Follow the
rest of the assembly instructions in reverse.
Packing the kayak in the bag
In the large duffel-bag, place the padded seats on the bottom.
Lay crosspieces on top of the seats. The aluminum frame
sections go in next. Tuck remaining small items (ie: hatch rims,
rudder) into available space. The skin goes into the black pack-
cloth bag.
Carrying a loaded Kayak
Handles at ends of kayak are for carrying. A webbing loop
passed under the hull at the bow and stern ends and around
the shoulders will make lifting easier. Do not lift a loaded
kayak. Do not pull or drag the boat using D-rings on deck.
Storage
Once dry, the kayak can be stored assembled or disassembled
in a shaded, dry place.
Feathercraft K2 Expedition Double 6
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Feathercraft K2 Expedition Double 7
Chine Bars
Cockpit Rebars
Bow Chines
Skin
Foot Braces
Stern
Chines
Mast/
Deck Bar
Bow Section
Stern Section
Gunwale Bar Sections Keel Bars
Rudder
Stern Foot Slings
(attached in stern seasock)
Crossribs
Hatch Rims
Seat Slings
Seats
Rim Inserts
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1 LAY OUT ALL FRAME PARTS AS SHOWN ON THE PREVIOUS PAGE.
2 FOLD OUT THE BOW END FRAME SECTION. #1 IS STAMPED
ON KEEL.
3 SLIDE #1 KEEL SECTION OVER BOW FRAME INSERT. LIFT PLASTIC
CONNECTORS TO LOCK INTO PLACE.
Feathercraft K2 Expedition Double 8
Plastic connectors
BOW
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4 ATTACH #1 CROSSRIB TO KEEL.
• Hold crosspiece at 45 angle with “pin” at the bottom fac-
ing the bow.
• Insert pin into the end of the single keel tube on the bow
end frame section.
• Bring crosspiece to vertical position. Attach gunwales to
side of crosspiece.
• With the plastic “wing” in the “up” position, slide pin on
crosspiece into hole on frame. Lock into position by turn-
ing “wing” down.
Feathercraft K2 Expedition Double 9
Wing
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5 ATTACH BOW CHINES (YELLOW TAPE).
• The bow chines have the yellow tape and foot brace track
attached.
• With the “twister” in the open position, line up the
dogpoint screw with the hole on the delrin block.
• Close the twister and lock into place.
Feathercraft K2 Expedition Double 10
Block in open position
Block in closed position
Dogpoint screw faces cockpit
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6 REPEAT STEPS #2 TO #5 TO ASSEMBLE THE STERN SECTION OF
THE FRAME.
7 UNROLL THE KAYAK SKIN.
Note: The rudder bracket is permanently attached to the stern
end of the kayak.
8 SLIDE BOW FRAME SECTION INTO THE BOW SECTION OF THE SKIN
• (The end with the Feathercraft logo is the bow.)
• Velcro tabs are attached to the center of the inside of the
hull. Open the tabs.
• Insert the frame section as far as it will go, snug to the
end. Use a “slide, lift” motion. Reaching through hatches
is also helpful to pull the frame into place.
• Repeat with the stern frame section.
• Wrap velcro closures around keel bars.
Feathercraft K2 Expedition Double 11
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9 INSTALL RIM INSERTS
Feathercraft K2 Expedition Double 12
Rim Insert
Stern
Slide into pocket on underside of coaming rim.
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10 ATTACH KEEL BAR SECTION.
• One keel section has the #5 stamped on it; the shorter piece
has no numbers stamped, but has a single aluminum plate
at one end and two plates at the other. Attach these two
sections together. The end with the two plates faces the
bow. Attach the #5 keel section to the #5 frame section.
11 ATTACH BOW AND STERN KEEL.
• Reach through the bow cockpit and lift keel up enough to
allow joining of the keel parts.
• Close black plastic tabs to lock into place.
Feathercraft K2 Expedition Double 13
#5 Keel Section
Bow
Mast step
Black Plastic Tabs
Bow
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12 TENSIONING FRAME INTO THE SKIN.
• Push down on keel section, forcing frame tight into the skin.
• Insert the hook “hinge” pin through the hole in the middle
of the hinge section to secure into place.
13 ATTACH GUNWALES (BLUE TAPE) TO THE STERN SECTION.
• The gunwale section is attached with the blue tape on the
top bar and the plastic connectors towards the stern.
Feathercraft K2 Expedition Double 14
Hook “hinge pin”
Stern
Stern
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14 LOCKING GUNWALE BARS INTO POSITION.
a) Reach through bow cockpit and interlock ends of
gunwale. Push out towards skin.
b) Twist aluminum tab on gunwale section to lock
into place. Do this on both sides.
15 INSERT #3 CROSSRIB FIRST.
• Lay crossrib horizontally between the gunwale frame-work.
• Push frame out and twist crossrib down into position.
• Repeat with crossribs #2 and #5.
• With crossrib #4, attach bottom thumbscrew then pull
gunwale bars in to meet the crossrib and insert side pins to
the frame.
Feathercraft K2 Expedition Double 15
Aluminum Tab
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16 INSERT CHINE BARS.
(shock-corked tube sections with yellow tape)
a) Open up chine bars with short section towards stern.
• Remember, it is easier to work on the frame work from
the opposite side.
• Tubes will slide easier when they are in-line with
each other.
• Slide chines into kayak under crossribs. Join with chine
tube at the bow section by pulling the bars into
alignment and sliding together. (If necessary, pull tube
towards center of skin to allow tubes to slide
easily together.)
b) Attach stern section by pulling tube apart, extending
shockcord and sliding tubes together. If necessary, pull
tube towards center of skin to align and slide. To slide
chine sleeve over shockcorded tube join, push the chine
section “out” towards the outside of the skin. When the
two chine tube sections are in line, pull back towards cen-
ter of skin, slide sleeve to secure join.
Feathercraft K2 Expedition Double 16
Stern
Chine Tube
Stern Chine Sleeve
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16 INSERT CHINE BARS.
(Continued from previous page)
c) Have the delrin latch (or “twister”) in the open position.
Insert the pin on the #3 cross rib into the delrin block.
Close the “twister”.
Feathercraft K2 Expedition Double 17
Stern
Block in open position Block in closed position
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17 INSTALL BOW AND STERN DECK BARS (GREEN TAPE).
Bow deck bar has single green tape. Stern deck bar has
double green tape.
a) Slide bow deck bar through the hole in the #2 crossrib,
and stern deck bar through hole in #5 crossrib. (Black plug
faces towards cockpit.)
b) Reach through hatch opening and connect with
forward deck bar with spring button.
Feathercraft K2 Expedition Double 18
Bow
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18 INSTALL MAST DECK BAR.
• Reach under deck between cockpits to slide mast deck bar
through holes in crosspiece. Locate mast hole towards bow
and holes in the ends of the tube facing up.
19 ATTACH COAMING BRACKET.
• Screw down coaming knob on bracket on crosspiece so
that bolt extends through hole in deckbar.
Feathercraft K2 Expedition Double 19
Bow
Mast Hole
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