Abstract: A kayak paddle having at least one paddle blade is made by laying a first resin impregnated fiber preforms in a lower half of a split mold. The split mold has a bifurcated channel for producing a bifurcated rib in a back face of the paddle blade. One end of a paddle shaft is inserted into a cylindrical recess in the lower mold half, and a bifurcated foam core in inserted in the lower mold half over the bifurcated channel. A second resin-impregnated fiber preform is laid over the first fiber preform, and an upper half of the split mold is closed over the lower mold half from one end in clam-shell fashion. Heat and pressure are applied to press the molds together to create thereby a fluid wall of liquid resin which advances through the fiber preforms as the mold closes, driving air out of the fabric preforms as the resin advances through the fiber preforms, and curing the resin to produce a solid fiber-reinforced resin matrix paddle blade bonded to the paddle shaft.

Abstract: The invention includes processes and products made by the processes. The processes include making a two-part mold having semi-cylindrical openings for the paddle shaft so that the paddle blade may be molded and co-cured directly on the paddle shaft. The mold surfaces correspond to the ultimate outer mold line of the paddle, and also are designed to express liquid resin from the centerline of the paddle outward toward its edges as the mold closes or to fuse and consolidate thermoplastic resin such as polypropylene on glass fiber. The mold closing and heating schedule is designed to partially cure the resin so that it flows outward through the reinforcing fiber at a controlled rate, preventing resin starvation of the fiber reinforcement and ensuring complete expulsion of any air bubbles in the reinforcing fiber. The mold is opened and the paddle is removed from the mold for trimming by a high speed CNC router to produce a paddle that conforms exactly to the desired peripheral shape.

Abstract: A kayak is disclosed having a cockpit for holding a paddler and having a deck with at least one hatch. The exterior mold line of the kayak presents smooth sleek lines that are uninterrupted by a protruding hatch cover or by unsightly straps and buckles holding the hatch lid in place. The kayak has a cockpit for receiving a paddler and at least one cargo hold with a water tight bulkhead between the cargo hold and the cockpit. A hatch well in the deck has a floor recessed below the level of the deck. A hatch rim is bonded and sealed in a hatch opening in the hatch well floor, and a water tight hatch cover is fitted on the rim to seal the hatch against ingress of water into the cargo hold. A peripheral recess around the hatch well receives the peripheral edge of a hatch lid, dimensioned to fit into the peripheral recess and lie flush with the deck. Retention rods protruding into the recess fore and aft hold the hatch lid against movement out of the recess.