Oru Kayak The Coast User manual

For your first assembly, avoid common mistakes by reading this Assembly Guide or watching
the assembly video at www.orukayak.com/assembly
BOW
(front)
Bow
fairing
Stern
fairing
STERN
(back)
Handle Handle
Cockpit
handles
Cockpit
BackrestDeck
buckles
Bulkhead
Bulkhead Bulkhead
Seam
channels
Seat
pad
Coaming
(cockpit rim)
Deck
straps
PMS 1665
c=0
m=68
y=100
k=0
r=243
g=115
b=33
US PATENT NO. 8,316,788
COAST
ASSEMBLY GUIDE
The

HOW TO GET STARTED
Read this entire Assembly Guide before
assembling your Oru Kayak.
Watch the instruction video:
www.orukayak.com/assembly
Check out our Tips & Tricks:
www.orukayak.com/tips-and-tricks
PLEASE NOTE
Your first time assembling may
take 20-30 minutes, but with
practice you’ll get closer to 10.
Be patient!
All Oru Kayak components have
been custom-engineered for a
precise fit. If a component seems
difficult to assemble, check the
directions instead of forcing a fit
that might not be correct.
WE’RE HERE TO HELP!
If you have questions, email us at
[e-mail].
Oru Kayak:
Explore outside the box.
With a few steps, the box you’re looking at will unfold into a six-
teen-foot long kayak that’s up for great adventures. It’s inspired
by the Japanese art of origami— and while it’s not quite as easy as
unfolding a piece of paper, your Oru Coast is designed to be simple
and intuitive to assemble.
With a bit of practice, the Coast can be put together in ten min-
utes—but the first time will take longer, as you learn the pro-
cess and the folds break in. Be patient and don’t force anything;
components are custom-engineered to fit together precisely. We
recommend doing it at home the first time, and also watching our
assembly video.
You’ll be on the water in no time at all, and we can’t wait to hear
about your Oru Kayak journeys. Send your photos and videos to
[e-mail] or add #orukayak to share them with the
community.
Enjoy your adventures!
The Oru Kayak team

WWW.ORUKAYAK.COM 1
A
B
C
Loosen and slide the
shoulder strap off
the sides of the box.
You won’t use it while
kayaking, but you will
need it when you fold
the Oru Kayak back into
box form.
Unclip the two sets of
box buckles on both
sides of the orange lid.
Lift the lid off.
Remove the loose kayak
components packed into
the box. See page 2 for
a list of the loose
components. Several
additional components
are permanently at-
tached to the hull/deck.
Step 1: Open the Oru Kayak box
The box contains all the components needed for assembly.
B
A
The lid
becomes
the kayak’s
floorboard.
The box becomes
the kayak’s hull
and deck.
23456789101

2 ORU KAYAK | ASSEMBLY GUIDE
Shoulder strap: Used to
carry the kayak when in
box form. Stow behind the
backrest while kayaking.
Loose seam channels (4):
Help seal the deck seam.
Cockpit bulkhead (large):
Provides structural rigidity
behind the cockpit.
Stern bulkhead (small):
Provides structural rigidity
in the kayak’s stern (back).
Backrest: Combines back
support and structural
rigidity.
Seat pad: Tucks under the
shock cord in the floorboard.
Deck straps (2): Stash
extra gear under these
rubber straps on the
kayak deck.
Spare parts: Extra
hardware for repairs or
replacements.
1
2
3
4
5 7
6 8
Parts: loose components
2
4 SEAM
CHANNELS
1
SHOULDER
STRAP
4
STERN
BULKHEAD
3
COCKPIT
BULKHEAD
2 DECK
STRAPS
75
BACKREST
6
SEAT PAD SPARE
PARTS
8

WWW.ORUKAYAK.COM 3
Step 2: Unfold the box
Hold the two folds at the
orange stickers. Pull as
indicated in the illustra-
tion (at left) to open.
Push the ends apart to
extend the box into a long
sheet.
Push down on any folds
that are bending inwards,
to pop the hull flat as you
extend it.
A
A
A
B
A
B
B
NOTE: Removable
orange stickers will
help guide you through
your first assembly.
3 4 5 6 7 8 9 103 4 5 6 7 8 9 101 2

4 ORU KAYAK | ASSEMBLY GUIDE
Fairings: These seal the
boat at the bow and stern,
and include handles for
carrying the kayak.
Deck buckles: Ten deck
buckles close the deck.
Bow (front) bulkhead:
Like the loose stern
bulkhead, this provides
structural rigidity.
Adjustable footrest:
Keeps your legs in a
comfortable position and
gives you greater control
of the kayak.
Coaming: The rim around
the cockpit can hold
a standard spray skirt
(size: medium) if desired.
Bulkhead hook:
This helps the footrest
pack more neatly when
the kayak folds into
the box.
End straps:
These straps help keep
the bow and stern tightly
closed.
1
5
6
7
2
3
4
Parts: hull/deck The box becomes the hull and deck of the kayak. Several key parts are permanently
attached to the hull/deck. The bow (front) and stern (back) of the Oru Kayak are
different, so pay attention to orientation throughout the assembly process.
1
2
6
2
3
4
7
5
5
BOW
(front)
STERN
(back)

WWW.ORUKAYAK.COM 5
Handles: Lock into
coaming and provide
support when entering
or exiting the kayak.
Backrest plate: Holds the
backrest and column (see
Step 9).
Seat pad shock cord:
The seat pad tucks under
the shock cord in the
center of the floorboard
(see Step 10).
Box buckles: Two sets
of buckles hold the box
closed, but are not used
when in kayak form.
Backrest
plate
Right cockpit
handle
Left cockpit
handle
Seat pad
shock cord
Box
Buckles
1
1
1
2
3
4
3
4
2
Parts: floorboard The box lid becomes the floorboard. The floorboard is a crucial part
of the Oru Kayak assembly: it locks into the cockpit at the coaming,
adding structure, and holds the seat pad and backrest.
STERN
BOW
NOTE:
If you like, you
can buckle these
together to keep
them out of the way
before assembling
the kayak.

A
B
B
The bulkhead hook keeps the front bulkhead and footrest out of the way while folding the kayak into
box form. The end straps and foam plugs keep the ends tightly closed.
6 ORU KAYAK | ASSEMBLY GUIDE
Step 3: Unhook bulkhead & tighten end straps
Unhook snaphook
from D-ring.
Tighten the end straps at
bow and stern, to help give
the kayak its basic shape.
Tuck foam block behind
tightened strap at bow and
stern, to fill space.
Push down on any folds
that are bending inwards.
Don’t be afraid to use a
little muscle.
A
C
B
D
CLOSE UP
Tuck foam
block behind
tightened strap
STERN
2 4 5 6 7 8 9 101 3
BOW
D
C

WWW.ORUKAYAK.COM 7
seam
channel
seam
channel
seam
channels
A
B
Step 4: Attach seam channels
Four seam channels seal the deck (top) of the kayak. Two are permanently attached
to one side of the deck, and you’ll attach the other two so that all four run
end-to-end for the entire length of the kayak.
Fit one loose seam
channel tightly end-to-end
with the permanently-
attached seam channel at
the bow. There should be
no gap between the two
seam channels. (See close
up.) Repeat with second
seam channel.
Repeat at the stern
of the kayak with third and
fourth seam channels.
A
B
CLOSE UP
The seam channels
attach end-to-end
as shown.
loose
seam
channel
no
space
permanently
attached seam
channel
STERN
2 3 5 6 7 8 9 101 4
BOW

Bow and stern bulkheads provide the Oru Kayak with structural rigidity. They do not
provide flotation. For extra buoyancy, place float bags (not included, but available
from Oru Kayak) between the bulkheads and the bow and stern.
Step 5: Insert bulkheads
Insert the bow bulkhead
(attached by a shock cord)
into the two black
U-channels affixed to
the hull at the bow.
Insert the cockpit bulk-
head into the two black
U-channels affixed to the
hull behind the cockpit.
Insert the stern bulkhead
into the two black
U-channels affixed to the
hull at the stern.
A
B
C
C
B
A
8 ORU KAYAK | ASSEMBLY GUIDE
2 4 6 7 8 9 101 35
BOW
STERN

WWW.ORUKAYAK.COM 9
Step 6: Close the cockpit
Rotate the front cockpit
rib to slide the keyhole
over the farthest shiny
screw.
Don’t worry about the
other screws yet.
Clip together the first
deck strap in front of the
cockpit.
Clip together the first deck
strap behind the cockpit.
If any folds bend inwards,
pop them back out.
A
B
C
D
C
This step puts the kayak into its basic shape.
Afront
cockpit
rib
NEED HELP WITH THIS STEP?
GO TO WWW.ORUKAYAK.COM/TIPS-AND-TRICKS
2 3 4 5 7 8 9 101 6
CLOSE UP
Slide the
keyhole over
farthest shiny
screw.
BOW
STERN
D

10 ORU KAYAK | ASSEMBLY GUIDE
Step 7: Insert the floorboard
The floorboard adds structure to the cockpit area.
The handles rotate and clip onto the coaming
(cockpit rim) to hold the floorboard in place.
Fold the floorboard into a
U-shape, and insert it into
the cockpit.
Flex the middle of the
floorboard upward, form-
ing a W-shape. Place the
edge of one handle into
the recessed groove in the
coaming, over the strap.
While pushing the middle
of the floorboard down,
rotate the handle to lock it
into place; the handle will
snap in when fully rotated.
Repeat with the other
handle. See close up.
A
B
C
Now rotate the handles
and lock them into
the coaming.
Fold the floorboard
into the hull. Flex the
middle of the
floorboard upward.
B C
NEED HELP WITH THIS STEP?
GO TO WWW.ORUKAYAK.COM/TIPS-AND-TRICKS
CLOSE UP
Handle goes over
coaming latch.
Rotate the cockpit
handle to lock into
the coaming, as
shown.
C
B
A
2 4 5 6 8 9 101 37
STERN

D
D
D
D
WWW.ORUKAYAK.COM 11
Step 8: Close the front of the kayak ALine up the shiny screws
with the slots in the front
cockpit rib.
Tighten the first deck strap,
sliding the shiny screws all
the way into the slots in the
front cockpit rib.
Close the front coaming
latch.
Clip together and tighten
the four remaining deck
buckles on the front,
starting at the cockpit and
working towards the bow.
Make sure that the edges
of both sides of the deck
slide completely into the
seam channels. See close
up.
Push downward on the
seam channel while pulling
on each strap to make it
easier.
CLOSE UP
Make sure the
black trim on the
deck slides entirely
into the seam
channels.
B
C
D
C
front
cockpit
rib
front
coaming
latch
B
A
deck
deck
trim
seam
channel
D
deck
2 3 4 5 6 7 9 101 8
BOW
STERN

Step 9: Close the back of the kayak
Closing the back of the kayak is
similar to closing the front (steps 7-8).
You’ll install the backrest column,
which supports the rear cockpit area.
Slide the backrest column
into the slotted backrest
plate in the floorboard. Tilt
upward to lock in place.
Place the two keyholes
in the backrest column
over the two shiny screws
below the kayak deck (see
close up). Slide screws
into slots to lock in place.
Close cockpit latch.
Clip and tighten the rear
deck buckles, as in Step 8,
starting at the stern.
Clip the buckle on each
side of the backrest into
the straps on the coaming.
B
A
C
D
E
C
B
CLOSE UP
How to lock the back-
rest column into the
cockpit and coaming.
This view shows
behind the backrest.
A
D
E
BOW
12 ORU KAYAK | ASSEMBLY GUIDE
NEED HELP WITH THIS STEP?
GO TO WWW.ORUKAYAK.COM/TIPS-AND-TRICKS
2 4 5 6 7 8 101 3 9
STERN

WWW.ORUKAYAK.COM 13
Step 10: Add the finishing touches
Confirm end straps are
fully tight, and bow and
stern are sealed with the
foam plugs.
Stretch the neoprene
fairings over the bow and
stern and clip the buckles
to the first deck buckles
at each end. Tuck the end
straps under the fairings.
Stretch the rubber deck
straps across the buttons
in front of the cockpit.
Slip the seat pad under
the shock cord on the
floorboard.
A
B
C
D
D
CLOSE UP
The notch of the
seat pad should
face the bow.
A
B
C
B
BOW
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STERN

14 ORU KAYAK | ASSEMBLY GUIDE
Final adjustments
Stash water bottles, spare
paddles, and other
accessories under the
rubber deck straps.
The coaming fits the Oru
Spray Skirt, or other skirts
(size: medium) if desired.
B
A
B
A
ASSEMBLY
CHECKLIST
n Bow and stern
straps are tight
and the fairings
cover both ends.
n Seam channels
are tight and no
deck trim is visible
underneath.
n All 10 deck buckles
are tight.
n Coaming is locked
at front and back of
the cockpit.
n Both cockpit
handles are locked
onto the coaming.
Congratulations!
Your Oru Kayak is
ready for the water.
BEFORE YOU GET IN:
ADJUST THE HEIGHT OF
THE BACKREST
Move the shock cord up
and down the notched
backrest column to
support your lower back.
ONCE YOU’RE IN:
ADJUST THE FOOTREST
From a seated position,
move the footrest by
loosening or tightening
the left and right buckles
just below the kayak deck,
in front of the cockpit
handles.
The footrest should keep
your legs comfortably
bent, with your knees
splayed outward.
BOW
STERN

Disassembling the Oru Kayak is basically
a simple reversal of the assembly.
However, there are a few tricks. Follow these
directions to learn how to pack your
Oru Kayak back into its box quickly and easily.
NOTE: Some water may collect inside the
plastic corrugations. To let it escape, stand
the assembled kayak vertically for about 10
minutes to let it drain out, before moving on
to Step 6.
The Oru Kayak box holds all the loose kayak
components. It may take a little practice to
find the best place for them all, but they do fit!
The shoulder strap makes it easy to carry the
Oru Kayak short distances; for longer trips we
recommend our Oru Pack, available at
www.orukayak.com.
Back on land: Folding your Oru Kayak into its box
WWW.ORUKAYAK.COM 15
Unclip the fairings and fully loosen the
end straps and unplu bow and stern
(as shown).
Open coaming latch, pull coaming apart,
and un-clip and remove the backrest.
IMPORTANT: Remove the four loose
seam channels (applied in Step 4).
Remove rubber deck straps, and unclip all
ten deck buckles. Loosen each deck
buckle to make your next assembly easier.
12
43

The big fold is an almost magical
transformation, from boat back to box.
Once you’ve removed all the detachable
parts, note that there are two asymmetrical
diagonal creases in the unfolded Oru Kayak
hull (see dotted lines, at right).
Note the black and orange arrows and targets
on the hull. You’ll use these to guide the next
step, in which you will fold the bow and stern
of the Oru Kayak inward—like an accordion.
The big fold
16 ORU KAYAK | ASSEMBLY GUIDE
DIAGONAL
CREASE
ORANGE
ARROW
BLACK
ARROW
ORANGE
TARGET
BLACK
TARGET
DIAGONAL
CREASE

With all loose components removed,
fold one end inward as shown. Push
down to invert that section into a V.
7
Remove the two bulkheads and hook
the bulkhead keeper to the D-ring, as
it was when you received your kayak.
6
Fold second fold inward, compressing
it like an accordion. Tightening the end
strap can help keep the skin in this
position.
8Repeat with the other end. Fold the two
accordioned ends towards the middle, to
slide past each other.
9Push the orange arrow towards the
orange target, and the black arrow
towards the black target. Continue
pushing, in a twisting motion, until the
arrows hit their targets!
10
WWW.ORUKAYAK.COM 17
Unlatch the front of the cockpit, and
remove the seat pad and floorboard.
Don’t be afraid to use a little force.
5

CARING FOR YOUR ORU KAYAK
• Inspect your kayak before each use
to make sure it is not damaged,
and that all fasteners are tight.
• Rinse off your kayak with clean,
fresh water after each use,
especially after paddling in salt
water.
• Make sure water does not collect
inside the kayak case after use.
• Some water may collect inside
the plastic corrugations. To let it
escape, flip the unfolded kayak
upside down to let it drain out.
• For additional cleaning, use
general-purpose cleaning spray
with a soft, non-abrasive rag or
sponge.
• In case of serious damage or
punctures, email us at
[e-mail].
0815 © 2015 ORU KAYAK, INC. ALL RIGHTS RESERVED
Push down to compress the box. Clip
together (but don’t tighten) the two sets
of outside deck buckles on either side.
Stash loose components in the box.
Tighten the side buckles and place the
floorboard over the top of the box.
Place and tighten the shoulder strap
loops over the box as shown.
All packed up and ready to go!
11 12
Folding the Oru Kayak back into the box
STASH
LOOSE
COMPONENTS
HERE
13 14