Canoes with fine woodwork are a tradition at Mad River Canoe. Hang the top curve over the side of the hull and put the outwale in the bottom curve. Caution should be used not to drill through the inner most part of the gunwale. The gunwales take a more circuitous route from end to end. Also available in cherry. Angle should run so that end against hull will be closest to deck. Treat underside of decks with Gunwale Guard and allow to dry before commencing installation. A better job results if all the rails are of the same age and moisture content. This is not a problem. Drill from inside of canoe towards outside, making sure that drill does not go all the way through outside of gunwale. This is normal as the hull tends to spread when components are removed. Mad River Canoe Cane Seat Stained 32." Cut outwales at a slight angle with point of junction of outwales forming the point of the “V”. Mark point centered 1/2” from point of deck and then ½” from rear end of deck on each side. The second inwale must be cut to fit against this centerline and hull contour. (If you are performing complete gunwale replacement: Let the uncut inwale ride up and over the ends of the canoe.) I did a Mad River Malecite and a Perception HD-1 and an Old Town Penobscot this way. dylan schoelzel and emily schoelzel of salmon falls canoe steam bend gunwales… For best results run screws to just snug with drill and finish tightening by hand. These marks will serve as centering points for new rails. If you are replacing ash gunwales, simply remove all screws in the gunwales and the decks until gunwales and decks lift off canoe cleanly. It is recommended that to minimize the chances of stripping the screw heads, first back them out manually with a screwdriver and then remove with reversible drill with a #2 Phillips head bit. How to Make Wooden Canoe Gunwales 1. We began by cradling the broken boat in slings—short sawhorse-height stands made for the purpose—and removed the breastplates, gunwales, seats, and thwarts. Make sure to coat the ends of the gunwales and if during installation you trim the ends, to coat the newly exposed surfaces. The easiest way to tell the size of your hardware is to look at the bolt heads. If fit is good, cover ends of new inwale and ends of existing end pieces with glue. need to be marked on the hull before removal. Holding the rail in place over stem of canoe, trace contour of stem of canoe onto rail so that rail will conform to hull shape. All of these situations can result in changes to deck size such that the deck for a 1978 Explorer can vary significantly from that for a 2008 Explorer. You can do this by drilling a ¼” hole vertically through nose of the deck and through the gunwales below or you can drill ¼” hole at an angle through the top of the stem of the canoe. Mark rail screw locations on inside of hull just below the rail, except at ends of canoe where marks will have to be made on outside of hull. One for a complete re-rail including new decks and another detailing a splicing process that allows the use of original decks. New gunwales are then clamped to the hull and tamped down to ensure they are properly seated. Reposition decks on canoe and drive #8 x 1” Phillips head screws into gunwales below decks to secure decks. Timeless and Rugged. Drill a ¼” hole through junction at ends of inwale to provide drainage for any trapped water when canoe is inverted. *C-clamps with round clamp surfaces can tend to walk off the gunwale as you tighten the clamps. The rails are already dipped in a penetrating oil at the factory. Begin the Build According To Your Boat/Ship Type:-If you have a canoe, the gunwale will be located at the top of the side of the boat. To re-rail a 14' or shorter canoe you will need 15' gunwales, 15' or 16' canoes will require 17' gunwales, etc. Pair of 18 ft canoe gunwales. Salmon falls canoe steam bending gunwales - youtube, A short video demonstrating steam bending. Seats, yoke, thwart or carry handles are then reinstalled at original locatons and finally a coat of oil is applied for maximum protection. Clamp new inwales to old inwales to make sure they stay in place. Additional sealing with penetrating oil such as Gunwale GuardTM before installation is recommended, especially on gunwale surface that will be installed against hull surface. This system is very suitable for replacement of squared gunwales but may necessitate replacement of the decks as well. The kerf is a small extension that will cover the top of the hull laminate. on inside of hull with grease pencil or washable marker. Remove the screws located approximately 12" from end of decks. Lay new gunwales on top of old and determine which fits best on each side of canoe and label them as such. This process is described at the end of the following instructions. Prior to 1985, Mad River Canoes were outfitted with square gunwales. (If you are short-splicing the installation, let the cut ends of the inwales float inside the canoe. 80 1 ½” stainless steel screws, original or replacement (attachment of gunwale to hull), 12 1” truss head stainless steel screws, original or replacement (attachment of deck to gunwale), 2 or 3 quick action spring or bar clamps are helpful, Wax pencil or similar non-permanent marker. Hook an “S” hook over hull at each end and put the ends of the outwale in the bottom curve. Apply fresh coat of oil to top and sides of new gunwales. Dip brush into Gunwale Guard and apply to gunwales from end to end. If you're not within driving distance, consider the ash Knockdown Gunwale kit. Replacement gunwales with Mad River profile. Aluminum Gunwale Replacement for Composite Hulls As a lightweight option on our composite hulls, Mad River Canoe offers black powder-coated aluminum gunwales. The inwale will need to be trimmed to fit inside end of canoe. It is always good to retain original decks if you can. It is best to cut conservatively and hand shape with file or sandpaper to achieve best results. This in turn leads to deterioration of the gunwale from within. If using 3/16” hardware, slide cupped finish washer onto bolt and bolt into hole. Wipe clean and apply Gunwale Guard as described above. If you have an older model canoe and the decks are glued to the gunwales, you may want to consider the “short-splicing” process that allows you to utilize those existing decks. Used primarily for Gunnel and Top deck installation and repair. Mark and trim the new inwale 3” short of end of deck at each end. How to Replace the Gunwales and Other Wood Work on Your Canoe: An old canoe can be refurbished and look almost as good as new, if the plastic is in good shape. Leave other rail. Tighten lock washers and nuts until contacting bottom of component. It looks like you may need to call to talk to them about the correct gunwales for your canoe. Older rails, especially if they have not been re-oiled, will be brittle and can break more readily than new ones soaked in a penetrating finish such as Gunwale Guard. Check to see that new gunwales are on line with line traced on hull at bottom of original gunwales. If you are performing a complete re-rail with new decks: The inwale will need to be trimmed to fit inside end of canoe. In 1985, a new lighter rounded profile was introduced and all replacement gunwales are rounded. Replace Mad River gunwale, seats, carry yoke? We stock full-length wood and aluminum canoe gunwales from Bell, Mad River and Old Town, plus hard to find stainless hardware. Step away from canoe and sight along rail to make sure it runs fair. Oiling Wooden Gunwales – from Mad River Canoe > Installing wooden gunwales – from Northwest Canoe > secure rails to hull. The hardware was changed in the late 1990’s to 3/16” to allow for double bolting yokes for stability and saving weight. Using 11/64" tapered bit and countersink, drill holes for deck screws at marks. Existing gunwales are next removed from hull with care being taken to protect original hardware upon removal. Work towards one end aligning gunwales with top of hull and with each. available in lengths from 14' to 20'. The rails are not pre-bent or pre-drilled but are flexible enough to follow the shape of the canoe by just clamping them to the hull. … Last fall one of them broke. Trace outside of seat hangers to provide accurate reinstallation. Remove countersink and drill other holes deeper and insert 2” screws in other locations and tighten. This makes this section a bit longer than the corresponding instructions for other types of rails. Check to see that bottom of new rails are even with line traced on hull in step #4. Allow 5 to 10 minutes for oil to be absorbed into wood. Move towards each end spacing marks 6” apart along the length of the rail. If you are concerned with maintaining shape especially if gunwale replacement may take extended period of time, make a brace from a 2 x 4 notched at same width as canoe's original beam and slide over top of hull. Lightly tamp down on top of rails with rubber mallet to seat rails flush with top of hull. Attach all hardware to each component to prevent loss. Adjust position as necessary. Due to their length, ash rails cannot be sent UPS. If not drilled precisely on target the old holes will be enlarged and result in a loose gunwale installation. Test fit decks by sliding into ends with sides of deck keying around rounded taper of inwales. It may be necessary to make adjustments to accommodate existing deck designs. Keeping your old decks can ease the “pain” of having to come up with a replacement if current factory parts do not fit. Older hardware can be recycled during a re-rail. If you wish to replace stained rails, it is best to stain them to match existing rails before installing them on the boat. Slotted rails have cutaways evenly spaced through the central third of the gunwale. Brush a coat of Gunwale Guard on the shank of the hardware before inserting hardware into hole. Due to the length of these gunwales, they must ship via freight carrier on a tractor trailer. Starting at center point and working towards first one end and then the other, using drill with 11/64" TAPERED bit and countersink, drill holes as marks along the rails. Prior to removing original gunwales, the locations of the seats, yoke, thwart, etc. On Royalex hulls, space screw holes at 6" intervals. Older model decks may no longer be available and you should factor this into your plans. If stained rails are desired, stain rails prior to installation for best results. Sand top and sides of gunwales and decks with 120 grit sandpaper to smooth finish and remove any pencil marks. The canoe world is full of one year wonders and hucksters that only talk a good game. A better job results if all the rails are of the same age and moisture content. At narrow end, it is necessary to offset the first two screws so that they do not conflict with one another. This hole will encourage drainage of water when canoe is inverted for storage or transport. Once the rail is tapped down as far as it can go, the rails can be re-drilled and re-riveted. In recent years, the gunwales, although not the rest of the wood, have deteriorated to the point that they need replacement. Mark location of all thwarts/yokes, seats, carry handles on hull of canoe with marker. Flip canoe over onto gunwales and mix up some glue with the saved sawdust and use mixture to fill the “V” shaped void at each end of canoe where outwales meet. The new gunwales also need to treated with a fresh coat of oil. These lines will help assure that the new gunwales are seated properly on the hull. Replacement one piece aluminum gunwales are available for Mad River Explorer and Malecite models of composite Mad River Canoes. The instructions that follow are written for the installation of kerfed gunwales but most of the steps are consistent for either gunwale style. Slotted inwales are available at additional cost. My experience with oiled gunnels, especially Mad River, is that they rot from the inside. Be cautious not to strip screw heads. In most of the wooden boats, gunwale remains mounted inboard. On composite canoes, the outwale has a “kerf” on the upper surface. The best alternative is to coordinate an order for replacement gunwales with a boat delivery to your dealer. One person to hold the rail straight and about 2 feet above the canoe edge, the other to start the end of the rail over the canoe edge and tap it in place with a rubber mallet. Starting from one end loosen and remove screws along one side of canoe. Set inwale in place at end of hull and clamp. Lightly tamp top of bolt to set bolt throat in wood and tighten fully. Reinstall components. Mad River Canoe does not recommend the use of varnish to protect gunwales. The only hardware available is 3/16”. Locate the marks defining seat locations, yoke/thwart, carry handles, etc. Remove all screws securing gunwales to canoe. The Malecite, a 16.5-foot … If additional information is required, contact your Authorized Mad River Canoe Dealer or call Mad River Customer Service @ 888/525-2925. If your canoe has the square gunwales, you will need to plan to replace the decks as well as the gunwales. The use of cardboard squares inserted between the clamp and rail will lessen the compression of rail by the C clamps and provide easier clamping. The second inwale must be cut to fit against this centerline and hull contour. It is recommended to drill new holes evenly. For best results, however, it is recommended that you replace gunwales as a complete set. AA611D Rivet. It is recommended that to minimize the chances of stripping the screw heads, first back them out manually with a screwdriver and then remove with reversible drill with a #2 Phillips head bit. Tighten hardware firmly but do not over torque as it is possible to sheer off stainless steel if over tightened. from canoe. Set saw just inside lines and trim off rail to form rounded end with straight side at center of canoe stem. You will use the S hooks to hold the ends of the gunwales close to the hull as you begin to clamp them at the middle. Screws are driven through hull and both inside and outside gunwales to secure gunwales starting from center of canoe and working towards one end and then the other. You may have to fabricate your own deck. Also trace line of bottom of rail on hull. Run tape measure around hull under existing rail. Support gunwales at waist height. At that time, Mad River switched to a rounded rail system for a more elegant, finished look and lighter weight. Remove all thwarts/yokes, seats, etc. Once you’ve reached end of canoe, return to center point and repeat procedure to opposite end of canoe. Clamp as needed to maintain position. Mad River Canoe stocks decks for current canoe models and those that have been discontinued for 3 years or less. Due to their length, ash rails cannot be sent UPS. If you are short-splicing the repair, leave these intact and clamp the remaining deck/gunwale ends assembly to the hull. 17' Ash Wood, Kerfed Gunwales for Composite Canoes up to 16'5". Take some scrap cardboard and cut into 2” squares and put squares of cardboard between clamp and gunwale to provide better grip and reduce tendency to walk. On the average, 80 screws are required to refasten a 16' canoe. Replacement ash rails are available that will fit all Mad River Royalex canoes regardless of age. Gunwales of appropriate length: 1 to replace single inwale or outwale, 2 to replace gunwales along one side, 4 for complete re-rail. Mad River founder Jim Henry built the first Malecite canoe in 1971. Collect a handful of sawdust and set aside. Angle bit so that the interior end of hole will be just below the bottom edge of the inwales. The T-Formex Remake. Ideally, the outer edge of the deck will overlap onto the outwale, concealing the top edge of the hull. It is an option to use non-kerfed gunwales intended for Royalex hulls on a composite hull if your dealer has such gunwales in stock. The gunwales will need to be longer than the length of your canoe as length is measured straight along the keel line while the gunwales take a more circuitous route from stem to stem. @ 888/525-2925. To re-rail a 14' or shorter canoe you will need 15' gunwales, 15' or 16' canoes will require 17' gunwales, etc. Start screws in holes and run up tight with Phillips screwdriver or drill fitted with P2 bit. Ideally, decks will fit snugly against junction of inwales at stem of canoe. Take some scrap cardboard and cut into 2” squares and put squares of cardboard between clamp and gunwale to provide better grip and reduce tendency to walk. It is recommended to have a package (12) of screws available should you inadvertently strip a few. There are two alternative processes described in the instructions. The rails are not pre-bent or pre-drilled, but are flexible enough to follow the shape of the canoe by just clamping them to the hull. The best alternative s to coordinate an order for replacement gunwales with a boat delivery to your dealer. At marks, drill 1/4" holes if using 3/16” hardware and 5/16” holes for ¼” hardware. The screws that connect the decks to the gunwales are 2” or 2 ½” long and should be removed slowly if you are doing a complete rerail. If they are glued, you will need to order replacement decks as well as new gunwales. It is critical that the gunwales be fully seated on the hull, especially in the area where the sides of the hull begin to transition to the rise at the ends. The best alternative s to coordinate an order for replacement gunwales with a boat delivery to your dealer. Once components are secure, place deck over end of canoe and judge fit. Original Decks will lift off of hull with the old gunwales. If getting the deck all the way up into position in end requires hull to be spread slightly that does not create a problem. It is preferable to drill new holes than try to re-use old holes. The best alternative is to coordinate an order for replacement gunwales with a boat delivery to your dealer. As you approach end of canoe it will become necessary to drill rails from outside of hull when hull is not wide enough to allow drill to align properly. Due to their length, ash rails cannot be sent UPS. Check other end as well. Center the holes in the inwale and take care to drill vertically so that hardware can drop through holes and will not contact inside of hull. Below component, place flat washer and lock nut and start nut. Run tape measure around hull under existing rail. So with a saws all I cut away the entire gunwale with an inch of the ribs down to good wood. Make straight line at end of rail by sighting down to opposite end of canoe along keel line. sedges: "I've had lots of wood gunnel canoes come through my shop for gunnel repair or replacement over the years. spaced between the old, as it is a hit or miss proposition to accurately drill through old holes. Please note that you will need to pick your gunwales up from the terminal. Let sit for 5 to 10 minutes and wipe off excess. Mad river canoe wood gunwale repair - that can help build the interest your readers are usually pleased in making these pages. On the average, 80 screws are required to refasten a 16' canoe. Insert 1 ¼” screws in first two locations and secure. While we do not sell replacement parts for Mad River Canoes, you can get them from edscanoe.com.You can see what they offer on their Mad River Canoe replacement page. Once these are secured you can release clamps at center.14. When fitting the ends of inwale inside stem, trace not only shape of stem of hull but also mark where other inwale will contact and cut accordingly. Mad River Canoe has used a variety of woods for decks over the years, ranging from mahogany to butternut to walnut to beech. It made the canoe an inch and half shallower. Varnish is a brittle top coat protection that will be broken down as the gunwale flexs under normal use. I have an old Mad River Explorer. Repeat for opposite end of canoe. Mark center point of hull on each side of hull. Hang the top curve over the side of the hull and put the outwale in the bottom curve. Repeat process at other end of canoe. ** “S” hooks can be made easily from a wire clothes hanger. Snug up nut until lock washer is aligned flat. On older model Kevlar/Airex models with foam core, the rails were glued to the hull as well as screwed and this can make complete removal more challenging. It is likely you’ll need to squeeze the sides of the canoe together to fit the yoke in place. Trace outside of seat hangers to provide accurate reinstallation. Old Town Canoe. You can use your original hardware or convert your canoe to current standards. The screws provide adequate purchase to secure the decks in place. Align new gunwales on hull, matching center line marked on hull with center line marked on each gunwale piece. Wood Gunwale Replacement for Royalex Hulls. Return to original end and wipe up any glue that may have run down from gunwale. It is best to cut conservatively and hand shape with file or sandpaper to achieve best results. A Lightweight Canoe for All Occasions Named Named “Best Canoe" – 2019 Paddling Magazine Industry Awards Matching the most versatile hull design on the market with the quality and refinement it deserves, the new Explorer Carbon features resin infusion for a lightweight and durable construction, contoured cherry outfitting, and integrated carbon/aramid gunwales. Currently, our decks are made of beech, a native American hardwood with excellent stability and durability and just as importantly, a wood that is well-managed and replenished. Replacement gunwales will need to be treated with Gunwale Guard or equivalent penetrating oil before installation. Installing wood gunwales does require a bit more craftsmanship than attaching synthetic gunwales. Mark center point with pencil on top and side of rails. Working towards one end, align rails even with top of hull. They can be merely ornamental or can be used to tie in gear or be used to set the canoe up as a hunting blind. Bend the opposite curve at a slight angle to the bottom. Set saw just inside lines and trim off rail to form rounded end with straight side at center of canoe stem. Here is a pdf file from Mad River Canoe on gunwale replacement that might be of some help: ... My stems are made from inner decks and outer sections that take up the section that the 16ft gunwales come up short. It is necessary to order rails longer than the length of your canoe to accommodate the curvature of the hull. On 3/16” hardware, place dimpled finish washer over bolt before inserting into gunwale and secure at bottom with flat washer and locknut. Hang “S” hooks over hull at each end and place ends of rail in bottom curl. Unclamp new rail and set aside. But, some canoes with large upswept en Clamp rail as needed, usually every 24-30". Start your gunwale replacement project by visiting or calling North West Canoe. Lightly sand top and sides of gunwales with progression of sandpaper grits. Once glue has set on each joint, drill hole bisecting angle cut and secure with screw. Maurice, Thanks for reaching out and thank you for working to bring new life to what I am sure is a beautiful canoe! Repeat steps #9-17 on opposite rail. Most of the more complex steps occur at the ends of the canoe, from fitting the inwales (inside gunwales) to the stem of the boat and the decks. I bought it used 15 years ago and replaced all the wood, then used it hard. In most cases, the original rail screws are reusable as they are stainless steel and resistant to corrosion. If using ¼” hardware insert bolts through rail and reinstall components. Mad River Canoe. It is possible to replace a single outwale or inwale or the gunwales along one side if desired. Oak Orchard only recommends canoe models which are proven in real use. Slide a piece of wax paper between inwale and hull and then fit the ends together and clamp. Even though the outwales are not trimmed at this point, they can be positioned properly to allow installation of screws to secure gunwales. right or left to ensure proper reinstallation. 80 pack of #8 x 1 ¼” stainless steel screws (if existing hardware cannot be used). Slotted rails do cost more than solid rails. ... talk to any canoe dealer that can supply Mad River products. Back in the days of wood-canvas canoes ash was the preferred wood for framing because it had a good strength-to-weight ratio and was also flexible and didn’t discolor during the steam-bending process. 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