Feathercraft Khatsalano 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]
Khatsalano
with built-in coaming
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Contents
Khatsalano Single Folding Kayak ..........................................Page 2
Specifications ........................................................................Page 3
Khatsalano Frame..................................................................Page 4
Care and Maintenance ..........................................................Page 5
Khatsalano Assembly Instructions.........................................Page 7
Disassembly ..........................................................................Page 29
Feathercraft Khatsalano 1
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Khatsalano Single Folding Kayak
Feathercraft Khatsalano 2
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Feathercraft Khatsalano 3
Khatsalano
Length: 5.4 m (17'10")
Beam: 56 cm (22")
Weight: 20.5 kg (45 lbs)
Depth: 29cm (11.5)
Travel Style Pack Bag Size: 94 x 46 x 24 cm
(37 x 18 x 10")
Assembly time: 35 minutes
Approximate Pay Load: 136 kg (300 lbs)
Khatsalano-S
Length: 5.4 m (17'9")
Beam: 60 cm (23.5")
Weight: 22.25 kg (49 lbs)
Depth: 29cm (11.5”)
Travel Style Pack Bag Size: 94 x 46 x 24 cm
(37 x 18 x 10")
Assembly time: 35 minutes
Approximate Pay Load: 145 kg (319 lbs)
Specifications
Frame: 6061 T6 Anodized Aluminum
Seamless Drawn Round Tubing
Crossribs: 1/2" High Density Polyethylene
Rivets & Spacers: Aluminum or Stainless Steel
Screws & Bolts: Stainless Steel
Protective Coating: Clear Anodized Aluminum Frame
Deck: Polytech
Hull: Duratek
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.
Sponsons: Welded Urethane
Standard Accessories:Neoprene Spray Skirt
Bow and Stern End Float Bags
Adjustable Foot Braces
Repair Kit
Travel-style backpack
Sea Sock
Shockcord Cross-deck Tie Downs
Perimeter Deck Line
Assembly Video and Written Instructions
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Feathercraft Khatsalano 4
Crossribs handcrafted from High Density Polyethylene
Welded Aluminum keel
(both bow and stern)
Stern deck bar/vertical lever
Total of five extension bars: keel, chines, gunwales
Secure bracing on diagonal truss bars
Reinforcement bars
Adjustable foot braces
Khatsalano Frame
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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 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.
SPONSONS
Due to 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.
Feathercraft Khatsalano 5
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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 each end of sponson. Pull spon-
son 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. Urethane glue and patches are included
in the repair kit. Duct tape works well on the sponsons.
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 bars apart.
Feathercraft Khatsalano 6
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Bow End
Mid Bow
Bow Cockpit
Hatch Rims
Mid Stern
Stern Cockpit
Horizontal lever
with foot track
Stern End
Keel Section
(Note: Keel bar is bent)
Feathercraft Khatsalano 7
1 SET OUT FRAME PARTS AS ILLUSTRATED.
Skin
Calf Plates
Cockpit Rim Inserts
Stern Deck Bar / Vertical Lever
Cockpit Rebar
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2 BOW SECTION.
• The Bow Rib tubes have a single band of coloured tape
(red, green, yellow, blue and black).
• The Bow Reinforcement Bars have one band of coloured
tape and one band of white tape.
• Fold out bow section. Shockcorded tubes take shape.
Attach second Bow Keel Assembly (with one welded plate
and two tubes attached, one black tape.)
• Attach keel bar with black plastic block and hole for
spring button.
3 ATTACH SMALL #1 CROSSRIB TO BOW SECTION.
• There are six high density polyethylene Crossribs.
Each one is numbered.
• Tilt crossrib above Keel Bar. Pin on small crossrib is inserted
into hole in plastic block on keel tube.
• Attach Gunwale tubes in notched connection on upper
section of crossrib.
Feathercraft Khatsalano 8
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4 ATTACH MID #2 CROSSRIB TO BOW SECTION.
• Attach keel as in Step 3.
• Attach to gunwales. Turn plastic block to lock into place.
Turn the tube so the two rivet heads face inward,
towards keel.
• Attach to Chines.
• Check that chines are properly aligned with #1 Rib.
5 ATTACH LEFT AND RIGHT BOW END REINFORCEMENT BARS.
(bent, with spring buttons: the right one with green tape
is shockcorded to section with foot track).
• Slide through the two holes in the #2 Crossrib and attach.
Feathercraft Khatsalano 9
Block in open position Block in closed position
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6 ASSEMBLE STERN SECTION.
• The Stern Rib tubes have two bands of coloured tape (red,
green, yellow, blue).
• The Stern Reinforcement Bars have two bands of coloured
tape and one band of white tape. The white tape of all
Reinforcement Bars is always oriented towards the bow of
the kayak frame.
• Repeat Steps #2,#3,#4, and #5.
7 ROLL OUT SKIN.
• Slide Bow and Stern sections into skin. (Feathercraft label
is on the bow end).
• Ensure that the frame is centered in the skin!
• Attach the two velcro closures on the inside keel of the
hull to keep the frame in place.
Feathercraft Khatsalano 10
Bow Stern
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8 INSTALL KEEL EXTENSION BAR.
• Wrap velcro closure around tube.
9 EXPAND KEEL EXTENSION BAR.
• Attach Keel bar to bow and stern section Keel bars.
• Lever extension bar using Stern Deck Bar/ Vertical Lever
and Bow Deck Bar/Horizontal Lever.
• Expand until spring button pops up in first hole.
An additional “pusher” block has been installed on the
bow keel bar. If the bow and stern sections need to be
separated further to insert the keel bar, push against this
block using the lever bars.
10 INSTALL RIGHT (BLUE) AND LEFT (YELLOW) CHINE EXTENSION BARS.
• Expand Chine Extension Bars to first hole.
11 EXPAND KEEL EXTENSION BAR TO SECOND POSITION.
• Depress spring button. Lever until spring button pops up
into the third hole.
Keel extension bar
Horizontal lever with foot track Stern deck bar/
Vertical lever
During additional assembly steps, keep re-checking that the frame
has remained centred in the skin.
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12 EXPAND CHINE EXTENSION BARS TO SECOND POSITION.
• Note: There are four holes in the Keel Extension Bar and
three holes in the Chine and Gunwale Extension Bars.
Expand to these positions if the skin slackens after
extended use.
13 INSTALL SEAT SLING AND GUNWALE EXTENSION BARS.
• Stern end of seat sling has narrower stitching. Slide Left and
Right Gunwale Extension Bars through loops in sling.
Attach Gunwale Extension Bars to frame and expand to
first hole. Slide lower flaps of seat sling under Chine Bars.
(Do not attach velcro until #3 and #4 Crossribs are in place).
Expand Gunwales to second position.
• At this point ensure that the entire frame is straight. Look
down the entire kayak. You may have to rotate the bow or
stern end slightly.
Feathercraft Khatsalano 12
(Please Note: Some steps have been shown with frame only
for illustration purposes.)
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14 INSTALL #3 CROSSRIB.
• Place Crossrib directly above the keel and chine bars
(forward of the seat sling) and push down.
• Tilt the Crossrib back towards the Stern and engage the two
Gunwale bars.
• Straighten the crossrib and slide forward until it is near the
spring buttons that protrude from the keel and chine
extension bars.
• Rotate the keel and chine extension bars until the screws
that protrude from the crossrib align with the holes in the
black plastic blocks.
Note: (The lever bar can be used to help rotate tubes.
Insert pin into hole used when you extended the frame.
Rotate to align.)
• Rotate the two gunwale extension bars until the black blocks
attached to them face towards the middle of the cockpit.
• Depress one of the gunwale spring buttons and slide the
crossrib over it. Do the same with the chine and keel bars
and then the other gunwale and chine bars.
CALF PLATES
• Install the plastic plate supports by wrapping Velcro
around Crossrib #3.
Feathercraft Khatsalano 13
Calf Plates
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15 INSTALL #4 CROSSRIB.
• Position the #4 crossrib aft of the seat sling and complete
like #3.
• Complete seat sling by securing ”velcro sandwich” around
chine bars.
16 INSTALL BOW REINFORCEMENT BAR/
HORIZONTAL LEVER.
• Attach to Left Bow End Reinforcement Bar.
• Slide footbraces onto track.
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17 INSTALL BOW COCKPIT REINFORCEMENT BARS.
• Slide the two bars from the cockpit through the large holes
in the #3 Crossrib. Attach to the bow reinforcement bars.
18 INSTALL STERN COCKPIT REINFORCEMENT BARS.
• Slide the two bars from the cockpit through the large holes
in the #4 crossrib. Attach to stern end reinforcement bars.
Feathercraft Khatsalano 15
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19 CONNECT THE COCKPIT REINFORCEMENT BARS.
• Slide the sleeve on the stern bars over the bow bars until
the spring buttons pop up in the first holes.
• (The technique shown works best.)
20 INSTALL RIM INSERTS.
• Webbing strap wraps around gunwale
and thigh brace.
Feathercraft Khatsalano 16
Stern
Rim Insert
Slide into pocket on underside
of coaming rim
Gunwale Bar
Thigh Brace
pull tightly
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21 ATTACH WEB LOOPS TO #4 CROSSRIB.
• On the inside of the deck behind the #4 crossrib are pieces
of webbing. Install over crosspiece and then back through
the slot in the crosspiece. Secure to ladderlock buckle.
22 INSTALL STERN DECK BAR/VERTICAL LEVER.
• Put the stern deck bar through the center of the large #4
crossrib: end with black block pointing toward the stern.
Bring deck bar back through hole in top of #4 Crossrib.
Line up bar, and insert stern end into hole drilled into the
top of the #5 crossrib. Rotate deck bar to lock into place.
• Cinch web loops (#21) to hold firmly in place.
Feathercraft Khatsalano 17
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23 ATTACH HATCH RIMS.
Place the small plastic bow hatch rim over the opening on
the bow deck, with the small end towards the bow. Roll
the fabric over the rim. Repeat with the larger stern hatch.
Note: Remove hatch rim when rolling up skin.
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24 INSTALL SEAT.
• Loop webbing at top of seat over #4 crossrib and connect
to buckle.
• Loop webbing at front of seat around the side of #3 cross-
rib and connect to ladderlock buckle.
• Note: webbing goes above chine bar.
• Note: this seat has special side straps that enable it to be
used as a beach chair
Feathercraft Khatsalano 19
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