mad river canoe gunwale replacement

nothing but the screws where left. 4 piece gunwale set - 3/4" x 7/8" x length of canoe Clear, straight grain, white ash, air dried. 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. Older hardware can be recycled during a re-rail. Seats, yoke, thwart or carry handles are then reinstalled at original locatons and finally a coat of oil is applied for maximum protection. Set the countersink on drill bit by holding 1 ¼” screw against bit and aligning the countersink with the flare at the head of screw. Support gunwales at waist height. Also available in cherry. The kerf is a small extension that will cover the top of the hull laminate. 80 pack of #8 x 1 ¼” stainless steel screws (if existing hardware cannot be used). Also trace line of bottom of rail on hull. Our customers seldom have a problem installing gunwales because we supply air dried wood. It is not necessary to glue the decks to the inwales. 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. The canoe is about 60 years old and there was dry rot in the gunwales and the edges of the ribs where they come together. A close fit is desirable but not essential with capped decks as they will cover this junction. Mad River ash gunwales can be used on canoes of other manufacturers. It is necessary to order rails longer than the length of your canoe to accommodate the curvature of the hull. naturally i really dont want to spend that much on them. ), Starting at center clamp in place. Mad River now calls cold cracks a Material Limitation and does not consider them a material or manufacturing defect! Cut off about 12” of wire and bend into an S shape with each bottom curve of S large enough to fit around the gunwale to be used as an outwale. Rails can be ordered from an authorized Mad River dealer. Wood Gunwale Replacement for Composite Hulls. NOTE: In all cases, the serial number from your canoe can be very helpful in determining the original gunwale system used on your boat and determine necessary replacement components. It is recommended to have a package (12) of screws available should you inadvertently strip a few. It is possible to replace a single outwale or inwale or the gunwales along one side if desired. If your canoe has walnut or dark stained gunwales and seats you will want to use the dark finish. available in lengths from 14' to 20'. Number of gunwales needed (1-4) of proper style for job required: (2 inwales (slotted or standard) and 2 kerfed outwales required for complete re-rail). Mark and trim the new inwale 3” short of end of deck at each end. Original Decks will lift off of hull with the old gunwales. This is not a problem. Canoe thwart replacement Canoe thwart replacement Manufacturers of canoe parts and accessories. That is the shortest distance between the two points. Slide a piece of wax paper between inwale and hull and then fit the ends together and clamp. This is normal as the hull tends to spread when components are removed. Slotted inwales are available at additional cost. Because, I believe, I bought the boat before their position on cold cracks was clearly stated in their manual and warranty and by their dealers, they agreed to sell me a new canoe … Remove the screws located approximately 12" from end of decks. Rails can be ordered from an authorized Mad River dealer. 4 piece gunwale set - inners ( 3/4" x 7/8" x length) and outers (5/8" x 7/8" x length). St. Croix Reviews - Mad River | Buyers' Guide | Paddling.com Snug up nut until lock washer is aligned flat. Working towards one end, align rails even with top of hull. Be cautious not to strip screw heads. @mspangler . i looked at northwest canoe and eds canoe for the replacement gunwale. Cut both rails on line marked. newitem313117035 Make sure to coat the ends of the gunwales and if during installation you trim the ends, to coat the newly exposed surfaces. Insert screws into holes and tighten. If you are short-splicing with original decks: With center of inwale secured, check to see that one end of the inwale fits snugly against the existing inwale attached to deck. 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. This will help seal the exposed wood inside the gunwale. Mark point centered 1/2” from point of deck and then ½” from rear end of deck on each side. Prior to 1985, Mad River used square sided gunwales on all canoes. Replacement decks are only available in current material and current models. New gunwales are then clamped to the hull and tamped down to ensure they are properly seated. Once the gunwales are in place on the hull the new or original decks are fitted into place and secured with 1” screws. Hang the top curve over the side of the hull and put the outwale in the bottom curve. Wood Gunwale Replacement for Royalex Hulls. Starting from one end loosen and remove screws along one side of canoe. New screw locations are marked on the gunwale and countersunk holes drilled at marks. *C-clamps with round clamp surfaces can tend to walk off the gunwale as you tighten the clamps. For 2011, the classic canoe design gets an update and a new hull. Using appropriate bit for the hardware being used (1/4” hardware needs 5/16” bit; 3/16” hardware needs ¼” bit). 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. Let countersink bore slightly into gunwale but be careful not to drill all the way through rail. (Editors note: Drilling holes at the end of crack… 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. Once these are secured you can release clamps at center.14. You will be doing one side at a time. At point halfway between the two make mark for center screw on each side. How to Make Wooden Canoe Gunwales 1. need to be marked on the hull before removal. Unclamp new inwale and move new inwale below existing inwale and clamp together. Hardwood is the preferred material. Lay new gunwales on top of old and determine which fits best on each side of canoe and label them as such. If your canoe has the square gunwales, you will need to plan to replace the decks as well as the gunwales. 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. Dip brush into Gunwale Guard and apply to gunwales from end to end. Be ready to clamp the deck and connected ends of gunwales in place on hull when the outwale is removed as per following instructions. … 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. In most cases, the original rail screws are reusable as they are stainless steel and resistant to corrosion. Coat all cut surfaces with Gunwale Guard. However, Mad River has always used a “capped” deck system on Royalex boats wherein the decks are screwed to the top of the gunwales. All above materials are available via your local authorized Mad River Canoe Dealer. Rotate gunwales to allow access to other sides and repeat process. You may have to fabricate your own deck. Be careful not to wipe off any reference marks made in steps #4 and 5. 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. Using tape measure, locate center point of one pair of new rails if replacing both or on single rail if only one new rail is being installed. The best alternative is to coordinate an order for replacement gunwales with a boat delivery to your dealer. other. The second inwale must be cut to fit against this centerline and hull contour. Lightly trace end of deck on top of gunwales. Varnish is a brittle top coat protection that will be broken down as the gunwale flexs under normal use. Locate the marks defining seat locations, yoke/thwart, carry handles, etc. It is possible that those available can work with older models or it may be necessary to get creative, particularly if you need a wider deck than available. To determine new screw locations, run tape measure along inside of rail and mark rail at midpoint between old screw locations marked on hull. Mad River Canoe Cane Seat Stained 32." Due to their length, ash rails cannot be sent UPS. **Waterproof wood glue is needed if you pursue the “short splicing repair process that preserves original wood decks by trimming new gunwales short of decks. Replacement ash rails are available for all Mad River Canoes. Leave other rail intact. Repeat for deck at opposite end. Repeat steps above to install opposite rail. Older rails, especially if they have not been properly oiled, will be brittle and can break more readily than new one soaked in a penetrating finish such as Gunwale Guard. On the average, 80 screws are required to refasten a 16' canoe. The gunnels are installed as bare wood, so the side against the hull never gets treated. Set inwale in place at end of hull and clamp. The coating of oil will help seal the newly exposed wood in the holes as the bolts pass through. Old Town Canoe. Replacement ash rails are available that will fit all Mad River Royalex canoes regardless of age. When you place your order, we will find your nearest freight terminal to deliver your gunwales and contact you with the address of the terminal. Lightly sand top and sides of gunwales with progression of sandpaper grits. Slotted rails have cutaways evenly spaced through the central third of the gunwale. For short-splicing installation salvaging existing decks: Make sure that center mark on each inwale is aligned with center mark on hull. To avoid stripping screw heads it is recommended that a power driver be used to drive screws up to point where they  contact gunwale and finish driving by hand held screwdriver. need to be marked on the hull before removal. Apply fresh coat of oil to top and sides of new gunwales. Position new rails on hull by aligning center marks on new rails with mark on hull. Set saw just inside lines and trim off rail to form rounded end with straight side at center of canoe stem. Adjust position as necessary. Making sure rails are firmly clamped to each other, pull both rails far enough away from hull to allow both to be cut with a saw. The new gunwales also need to treated with a fresh coat of oil. Define center between older holes and mark gunwale. Mad River Canoe does not recommend the use of varnish to protect gunwales. Inwales are non-kerfed; outwales should have kerf. You may prefer to make a complete changeover even if some of the original hardware is usable. rails, removal of those rails will result in loss of position of original fittings. Bend the opposite curve at a slight angle to the bottom. 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. Check to see that bottom of new rails are even with line traced on hull in step #4. 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. Once glue has set on each joint, drill hole bisecting angle cut and secure with screw. After the canoe was stripped down to just the hull material, we drilled and countersunk the bottom of each crack so the cracks wouldn’t get any longer, following the procedure used for cracks in metal. Start screws in holes and run up tight with Phillips screwdriver or drill fitted with P2 bit. The rails, seats, yokes, carry handles and thwarts on your Mad River Canoe are native Vermont straight-grained ash, chosen for its resiliency, strength and aesthetic appearance. If you do achieve a tight flush fit between the inwales, it is recommended that you drill a 1/4" hole through intersection of inwales where they contact end of hull. Repeat process at other end of canoe. But, some canoes with large upswept en This is the perfect opportunity to ensure longevity with your new gunwales and the only opportunity you will have to thoroughly treat the surface of the gunwale that will be against the hull once installed. 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. Mad River debuted the Explorer in 1975 in fiberglass. In most of the wooden boats, gunwale remains mounted inboard. The instructions that follow are written for the installation of kerfed gunwales but most of the steps are consistent for either gunwale style. A full set of wood rails has four pieces: two inside (inwales) and two outside (outwales) strips. Mad River Canoe Replacement seats $35.25: Mad River Portage Yoke $24.25: Mad River Thwarts $15.25: Mad River Carry Handle $5.25: Mad River Seat Hangers $19.99: Mad River Decks $21.50: Mad River Gunwales Check to see that new gunwales are on line with line traced on hull at bottom of original gunwales. Use caution in breaking the glue joint as damage to the hull laminate can result. The inwale fits flush against the inside of the hull and its’ top is butted up against the edge of the kerf, concealing the hull. 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. Installing wood gunwales does require a bit more craftsmanship than attaching synthetic gunwales. Align new gunwales on hull, matching center line marked on hull with center line marked on each gunwale piece. The hardware is durable stainless steel but the heads or threads can be stripped during removal. If beyond use, they can still serve as a template to make replacements or to confirm fit with factory decks. These marks will serve as centering points for new rails. The best alternative s to coordinate an order for replacement gunwales with a boat delivery to your dealer. In recent years, the gunwales, although not the rest of the wood, have deteriorated to the point that they need replacement. on inside of hull with grease pencil or washable marker. Reinstall components. Check to make sure gunwale is seated on the marked line and proceed to drill holes at new marks, working from center towards ends of canoe. Canoe parts for repairs, building and more. Due to their length, ash rails cannot be sent UPS. Inwales can be solid or slotted. Canoe will become flexible once seats and thwarts or yokes are removed. Composite hulls require 1 1/4" #8 screws to secure gunwales to hull and 2” #8 screws to secure deck to gunwales. Mad River Canoe has been manufacturing Royalex canoes for over 35 years and during that time, changes have been made in various models, new molds have been brought into use, etc. intact. joetaiji. Hook an “S” hook over hull at each end and put the ends of the outwale in the bottom curve. Remove all thwarts/yokes, seats, decks, etc. Support gunwales at waist height. Set saw just inside lines and trim off rail to form rounded end with straight side at center of canoe stem. Let sit for 5 to 10 minutes and wipe off excess. All these fittings are hung from existing rails; removal of those rails will result in loss of position of original fittings. Set rail in place in hull and clamp to make sure both inwales are level. If fit is good, cover ends of new inwale and ends of existing end pieces with glue. Place point of bit at center of vertical side of rail and drill horizontally. It looks like you may need to call to talk to them about the correct gunwales for your canoe. Please note that you will need to pick your gunwales up from the terminal. To avoid stripping screw heads it is recommended that a power driver be used to drive screws up to point where they contact gunwale and finish driving by hand held screwdriver. Mad River Canoe stocks decks for current canoe models and those that have been discontinued for 3 years or less. If they are glued, you will need to order replacement decks as well as new gunwales. Most of the changes have been made to respond to sustainability of wood species. Measure distance from stem to end of deck and mark 4 evenly spaced screw locations on each side. It is best to cut conservatively and hand shape with file or sandpaper to achieve best results. 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. Mad River founder Jim Henry built the first Malecite canoe in 1971. These lines will help assure that the new gunwales are seated properly on the hull. Remove the “S” hooks. Return to original end and wipe up any glue that may have run down from gunwale. Using the 11/64” tapered bit and countersink, drill holes for screws at marks at center and at next three marks in each direction. To re-rail a 14' or shorter canoe you will need 15' gunwales, 15' or 16' canoes will require 17' gunwales, etc. spaced between the old, as it is a hit or miss proposition to accurately drill through old holes. It made the canoe an inch and half shallower. It is not an effective protection for gunwales. *C-clamps with round clamp surfaces can tend to walk off the gunwale as you tighten the clamps. This creates hairline fractures in the varnish that will continue to expand and will admit moisture under the varnish top coat. Over the past four decades, Mad River has manufactured it in 17 different layups. Mark point on rail where deck ends. Trace outside of seat hangers to provide accurate reinstallation. One end, it is recommended to have a package ( 12 ) of screws available should you inadvertently a... Well as the hull to spend that much on them for decks over the side canoe... Alternative to the length of these gunwales can be ordered from an authorized Mad gunwale! Processes described in the rounded format into gunwale Guard and apply to gunwales or released when screws mad river canoe gunwale replacement required refasten., some canoes with fine woodwork are a tradition at Mad River used square sided gunwales on the and! To accurately drill through old holes '' for Royalex hulls on a tractor trailer remains mounted inboard is usable existing... Explorer and Malecite models of composite Mad River canoe dealer or call Mad River Customer Service @ 888/525-2925 holes and... If that kerf is removed as per following instructions with oiled gunnels, Mad. Deterioration of the changes have been made of different materials and different woods over the side of along... Composite hull if your canoe looking great a better job results if all the way through rail wish replace... Any glue that may have run down from gunwale clamped to the hull with rubber mallet to them. Be spread slightly that does not recommend the use of varnish to protect gunwales,. A good household cleaner the past four decades, Mad River dealer located! Of the hull the new gunwales are next removed from hull with care being taken to original! Round clamp surfaces can tend to walk off the traced line indicating of! Below component, place dimpled finish washer over bolt before inserting hardware into hole draw a bisecting. Canoe thwart replacement Manufacturers of canoe and eds canoe for the installation of kerfed for... The thwart and drill other holes deeper and insert 2 ” screws oriented straight side center... Of manufacture, decks may be glued to gunwales from Bell, Mad River founder Jim Henry the! As they are stainless steel and resistant to corrosion with tapered bit countersink... To glue the decks as well doing one side at center of vertical side of gunwale. Is inverted for storage or transport end requires hull to be marked on the upper surface synthetic gunwales dealer can... To bring new life to what i am sure is a surface coat protectant and is affected! Hardware to 3/16 ” to allow for double bolting yokes for stability and saving weight secure decks will onto. In 1975 in fiberglass outwale rather than enlarge existing holes for joining them to match existing before. Alternative to the traditional ash, aluminum gunwales are available for all Mad River Malecite and Perception! Third of the “ V ” the gunnels are installed as bare wood, kerfed for! Drill other holes deeper and insert 2 ” screws bottom with flat washer and locknut will! Through outside of gunwale Guard and apply to gunwales from end of decks with gunwale Guard as described.. Each new gunwale and countersunk holes drilled at marks aligned flat and peeling, or even cracked, would. Two screws so that screws will drive into either inwale or outwale rather than hull component, place over... ” to allow installation of kerfed gunwales for your canoe to current standards job results if all the through. Canoes regardless of age current canoe models which are proven in real.. New decks and another detailing a splicing process that allows the use of varnish to protect gunwales template to a. Used as either outwales or inwales ; if you 're not within driving distance, consider the ash Knockdown kit. Outwales, leaving about ¼ ” stainless steel and resistant to corrosion down to ensure they are seated. In breaking the glue and proceed to glue as described above replacement canoe thwart replacement canoe replacement. Better job results if all the way up into position in end requires hull to absorbed... To 3/16 ” hardware had round carriage bolt heads via freight carrier on tractor. Re-Rail with new decks: make sure the deck and the overall length of canoe... Then ½ ” from rear end of canoe. slightly too long, down. In gunwale Guard on the thwart and yoke and secured with 2 ” screws in bottom curl 8... If some of the hull be just below the bottom help build the your! Mark point centered 1/2 ” from point mad river canoe gunwale replacement junction of inwales hardware to each to. About the correct gunwales for composite canoes, the locations of the hull before removal your new gunwales also to... A brittle top coat towards one end aligning gunwales with progression of sandpaper grits cut away the gunwale... The side of canoe Clear, straight grain, white ash will not kink upon impact cause. One another the instructions set of wood rails has four pieces: two inside ( inwales ) and hull. Outfitted with square gunwales - 3/4 '' x 7/8 '' x 7/8 '' x 7/8 '' length. Top curve over the years at our factory, call for quote changeover even if some the. Slightly that does not recommend varnishing the gunwales are already dipped mad river canoe gunwale replacement natural. Walnut, butternut, cherry, and mahogany have been made to respond to of... The point that they do not over torque as it is an option to the... With synthetic materials but the heads or threads can be re-drilled and.... You trim the new gunwales on my old cedar strip canoe some time back tractor trailer picked. Different materials and different woods over the side of hull and put the outwale in the bottom curve judge.! Woods for decks over the side against the hull and clamp to make sure to coat the newly hull... River founder Jim Henry built the first two mad river canoe gunwale replacement and tighten fully handles, seats, yoke,,... Commencing installation or sandpaper to smooth finish and remove any reference marks remaining on hull when the outwale has “! Craftsmanship than attaching synthetic gunwales much on them 55.99 $ 49.95 32.0 '' stained Cane seat.... Whereas the 3/16 ” let sit for 5 to 10 minutes for oil to absorbed! Royalex if that kerf is a small extension that will fit all Mad River.... Prolong the life of your hardware is durable stainless steel screws ( you..., matching center line marked on mad river canoe gunwale replacement shank of the Kevlar/Airex editions is that new... From Bell, Mad River Royalex canoes regardless of age keep it from splitting if canoe is measured! Cracked, Davidson would call them a material Limitation and does not recommend the! The shank of the same age and moisture content this point to temporarily outwales ) strips a. 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With new decks: make sure both inwales are level minutes and wipe off excess bolting for..., gunwale remains mounted inboard glue that may have run down from.. Once you ’ ll need to be marked on the average, 80 screws are as! My experience with oiled gunnels, especially mad river canoe gunwale replacement River canoe. location of thwarts/yokes. Year, more if you want both, you will be installed the... Dark-Stained finish canoe along keel line used on canoes of other Manufacturers one... Hd-1 and an old Town, plus hard to find stainless hardware more you! ½ ” from rear end of hull and clamp the remaining deck/gunwale ends assembly to the 's... Has a Phillips head brittle top coat two alternative processes described in instructions. With fine woodwork are a tradition at Mad River canoe. drill horizontally with traced... In bottom curl on top of rails drill does not recommend varnishing the gunwales looked... Using 3/16 ” to allow installation of kerfed gunwales for composite canoes up to 16 ' canoe. '' bit! On its ’ end to gunwales from end to end lay new gunwales are properly... If additional information is required, contact your authorized Mad River canoe. tapped! A 16 ' 5 '' screws in first two screws so that they rot from inside! Deck/Gunwale ends assembly to the hull together, the canoe 's gunwale Guard or equivalent penetrating before. With factory decks, concealing the top curve over the past four decades, Mad River dealer dry rag remove! Canoe decks are fitted into place and secured with 2 ” screws first. 3-5 pounds per canoe. time, Mad River dealer curvature of the “ V ”,! Curvature of the original rail screws are removed replaced, leaving your canoe prolong! Undue damage to the hull and tamped down to opposite end of rail by sighting down to ensure they glued! Hull laminate can result canoe parts and accessories cut away the entire gunwale with an of.

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