Kalash Layout shakedown..wet but not bloodied 1/7/12

Dave Diefenderfer

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I started on the next project this weekend. Moved a Kalash layout boat into the boat shop/tent, and set it on the sneakbox cradle after taking some pictures. Some history.... correct me if I get anything wrong Rufus. This layout is owned by Rufus Brinn, who had it built new for him while he was at West Point. Throughout his military career, the boat has been moved and stored all along the way. This layout is some 30 years old, and apparently has not ever been hunted! Rufus has finally assembled a posse, and a decoy collection sufficient to do an honest job of doing some layout hunting.

When I looked at the layout it was apparent to me that without doing some work, it could be hunted as is, but would not last more than a season or 2. The wood is extremely dry and the paint and glass tape on the seams is peeling up. It would float, but would not be water tight. I convinced Rufus, that a coat of paint was not sufficient, and we should hold off a season while we did the work correctly.

The plan is to strip off the paint, and any loose glass. Paint the hull with epoxy, to firm up the soft spots, fill with thickened epoxy were needed, then glass the hull top and bottom. Since we don't have a tender large enough yet to carry the layout in the boat, we will likely tow it. We also will not have to go more than a couple miles from the ramp. My plan is to mount towing mounts below the deck, so that we will lift the bow (really the stern). I think some ipe runners along the bottom edges on the port and starboard both to protect the edges, but also to offer some better hand hold when lifting along the sides. A ipe skeg will be attached to the bottom as well to help it track when being towed.

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What a great project, Dave. Don't you wish that boat could share the memories it has seen over the years?
Al
 
Yes Chris, this will be done for this season.... by December anyway... when the divers arrive.

Al, I don't think this boat has much to tell.... don't think it has ever been hunted! Stored for over 30 years.... moved several times I think.

Perhaps Rufus will chime in and offer more details....

Dave
 
Riley, my understanding is that this was built by John Kalash over 30 years ago. Rufus where are you...... give us the details!
 
Yep, it is a Kalash boat, transported down from Michigan in 1983 , if memory serves. I shipped out for Germany after that, so it spent most of its life in a buddy's tobacco barn down in North Carolina. Most bird activity it has seen was the nesting residue I took out of it when I retrieved it and brought it up to Northern Virginia. I think it was about $300 new, with a buddy picking it up somewhere in Kentucky along an interstate as the rest of the load headed south. With Dave's help, hope to have it ready for the divers in the late season this year!
 
Dave,can you stick a flashlight in one of the side pockets and take a picture? I am curious how the detail is constructed out on the feather edge. It looks like the coffin was edge nailed together and then taped with resin and cloth. Do you think it is epoxy? What is the weather like in the shed for sanding?

That is one of the nicest looking layout boats I have ever seen in shape. The hull looks deep for concealment and comfort but not too much flotation. I will be very interested to see how it floats and tows. Dont forget that a bridal can be run from up top under the hull to get the tow line deeper for lift.

Also remember that when restoring older ply boats, count every ounce you add. Things like wood and glass add up fast and the weight can go up quickly.

Again, great looking layout guys, keep us posted. Do any members here hunt one of these, have a float\ride report?
 
Bob, I'll get you some pictures if I have someone around to help me flip it again... if not in a few weeks, I'll get them posted. But is as you surmised. The coffin is edge nailed, taped and sealed with resin. I think polyester, I'll pay attention for odor when I sand again. The framing is all 2x simple cut out and nailed to the bottom plywood. Then the top is nailed over that. No floatation currently.

I am thinking a much lighter version could be made with all plywood and epoxy, and then glassed.

Weather for sanding? Hot in the Summer, and cold in the Winter! The tent has doors at both ends, and 4 windows. When I am sanding, I open the back door, place a fan at the front and fog the backyard with dust. A leaf blower on occasion cleans out the shop!

I am with you on the adding weight, and we will for sure be adding to the already heavy boat. I think the trade off in layout boats is just that.... heavy boats will ride tight and low, be a bitch to load or tow... and a light boat will be the opposite. We weighed this at 140lbs before we started... I expect to add maybe 20lbs to it, but it will be hopefully ready for generations to come, and maybe handle and tow somwhat better.

I removed the tow rings to start sanding, and will be adding mounting points on the bottom to attach a towing bridle. I expect we will need to snub this up tight to tow it. I have an idea for a simple tow post that will drop into the back handles and cleat off, and keep the line away from the OB. However, we maybe looking for another tender rig, as the member of our posse with the tender is looking at deployment in the Fall.

More pics to come as progress is made....

Dave

Is John Kalash still around? I have not done any research.... would love to talk to him.
 
John Kalash Layouts, 3595 Dennings Road Moscow, MI 49250, (517) 849-5022
I don't know if this info is current or not.
I spoke to John on the phone once and he is very interesting to talk to.
 
Bought one from John in 1984 on my honeymoon while traveling through michigan. Wife should have known then she was hitched to a duckboat queer. Still have it , use it a couple of times a season. Neeeds new canvas.
 
Thanks for the info Dave.
Tough one on the deployment. That does not look like a situation over there that is getting any easier each day.

Be careful on a stern mounted towing bit. The ideal point of attachment is ahead of the rudder on a tug and same for an outboard if the weather and wind is bad. The load on the tow line counters the effort of the motors thrust or rudders swing in cases where the rope is attached at or behind the same. Makes turning or going ahead with a wind on the beam darn hard. That layout isnt going to pull hard but you want all your facts straight before the season.
Test your ideas in the warm weather before a cold winter try out.

Stay cool in that shed.
 
Some progress. Rufus came over today, we finished sanding the bottom, painted it with epoxy, and filled all the voids.

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This week, I'll sand it again, and then layout the glass for the next full day of boat work we get. Likely won't be for at least a couple weeks, with the 4th being next weekend.

Dave
 
Dave that is one awesome boat! I love the lines on it, definitely has the wheels to churning. Can't wait to see the finished product and pictures along the way. Would love to have some measurements off of her as well if you get a chance.

Brad
 
No pictures, as not much progress, but we did get the hull sanded and the glass cut and fitted. Next full day of work will be to lay the glass. Hopefully on Saturday. Also need to order some more cloth for the decks. Several folks have asked about dimensional details of this boat. As it is a commercial boat, still in production of sorts, I am not comfortable posting up such details... sorry. It is Rufus' boat, I'll leave it to him to answer if he decides.

Dave
 
Started on the deck. Rufus and I sanded the deck and the inside of the cockpit, then followed up with a heavy soaking of epoxy to seal up the plywood. These photos are foggy because I brought out the camera into the high heat and humidity!

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Filled some of the voids with thickned epoxy this morning.... tomorrow evening we will sand and prepare for the glass work, maybe this weekend. Find that the cockpit is a little tight, we might remove the 2 inches of plywood back to the frames on both sides.... Rufus to try to reach John Kalash tonight to discuss....new canvas, and spray skirt support hardware on the way.

Dave
 
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Dave,
work looks good but HOT! Glad you guys are moving along.
Any guess on how much weight has been added? Looks like a great rig.

Bob
 
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