Feathercraft 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
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 1

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
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 1

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
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 2

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
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 3

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
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 4

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 Kahuna 5
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 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.
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
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 6

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
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 7

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 8
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 8

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
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 9

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
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 10

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
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 11

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
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 12

11 INSTALL SEAT SLING.
• The seat sling will be suspended from the chine and gun-
wale 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
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 13

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
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 14

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.
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”
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 15

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.
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 16

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.
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 17

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, push-
ing against inside of the deck.
Feathercraft Kahuna 18
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 18

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.
KahunaEnglish_Coaming 8/11/06 11:13 AM Page 19