to top of gunwales with pencil. Mark and trim the new inwale 3” short of end of deck at each end. 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. Run tape measure around hull under existing rail. 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. Composite hulls require 1 1/4" #8 screws to secure gunwales to hull and 2” #8 screws to secure deck to gunwales. 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. For maximum protection of your new gunwales, dip mounting hardware in Gunwale Guard before inserting into gunwales. The canoe world is full of one year wonders and hucksters that only talk a good game. Move towards each end spacing marks 6” apart along the length of the rail. This system is very suitable for replacement of squared gunwales but may necessitate replacement of the decks as well. The instructions that follow are written for the installation of kerfed gunwales but most of the steps are consistent for either gunwale style. Oak Orchard only recommends canoe models which are proven in real use. Decks on Royalex canoes have been made of different materials and different woods over the years. At that time, Mad River switched to a rounded rail system for a more elegant, finished look and lighter weight. Replacement decks are only available in current material and current models. New screw locations are marked on the gunwale and countersunk holes drilled at marks. For 2011, the classic canoe design gets an update and a new hull. To ensure that hardware is re-usable, it is best to start with a #2 manual Phillips screwdriver (for 3/16” hardware and rail screws) and start screws loose before using variable speed drill. 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. On 3/16” hardware, place dimpled finish washer over bolt before inserting into gunwale and secure at bottom with flat washer and locknut. i looked at northwest canoe and eds canoe for the replacement gunwale. Reposition decks on canoe and drive #8 x 1” Phillips head screws into gunwales below decks to secure decks. 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. You may have to fabricate your own deck. Reinstall components. Place point of bit at center of vertical side of rail and drill horizontally. Sand top and sides of gunwales and decks with 120 grit sandpaper to smooth finish and remove any pencil marks. Tighten lock washers and nuts until contacting bottom of component. Set inwale in place at end of hull and clamp. All these fittings are hung from existing. Also trace line of bottom of rail on hull. Hang the top curve over the side of the hull and put the outwale in the bottom curve. In most cases, the original rail screws are reusable as they are stainless steel and resistant to corrosion. Mark location of all thwarts/yokes, seats, carry handles on hull of canoe with marker. Tighten hardware firmly but do not over torque as it is possible to sheer off stainless steel if over tightened. 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. 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. Leave other rail intact. Replacement ash rails are available for all Mad River Canoes. For best results, however, it is recommended that you replace gunwales as a complete set. 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. If satisfied with fit, tape the deck in place with duct tap running from wide end of deck down center of deck and over stem. If getting the deck all the way up into position in end requires hull to be spread slightly that does not create a problem. Seats, yoke, thwart or carry handles are then reinstalled at original locatons and finally a coat of oil is applied for maximum protection. rails, removal of those rails will result in loss of position of original fittings. Mad river canoe wood gunwale repair - that can help build the interest your readers are usually pleased in making these pages. 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 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. MSRP: $55.99 $49.95 32.0" Stained Cane Seat is ... AA611D Canoe Repair / Gunwale Rivet, Black, Per each. This will strengthen that point and keep it from splitting if canoe is dropped on its’ end. The one thing you may want to be aware of is that ¼” stainless steel hardware is not available from Mad River Canoe and if you encounter some damaged hardware, you may end up with a “mixed bag” of hardware. Even though the outwales are not trimmed at this point, they can be positioned properly to allow installation of screws to secure gunwales. Check to see that new gunwales are on line with line traced on hull at bottom of original gunwales. 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. Existing gunwales are next removed from hull with care being taken to protect original hardware upon removal. Drill holes at marks with tapered bit and countersink. available in lengths from 14' to 20'. If you wish to replace stained rails, it is best to stain them to match existing rails before installing them on the boat. If your canoe has a few years on it, it’s wise to acquire a dozen or two of replacement screws in case of need. Be cautious not to strip screw heads. It is likely you’ll need to squeeze the sides of the canoe together to fit the yoke in place. The length of a canoe is usually measured down the center along the keel line. Prior to removing original gunwales, the locations of the seats, yoke, thwart, etc. Draw nut tight. Hang the top curve over the side of the hull and put the outwale in the bottom curve. How to Make Wooden Canoe Gunwales 1. The size change has more impact if you find out that your existing ¼” hardware cannot be re-used and has to be replaced. Make straight line at end of rail by sighting down to opposite end of canoe along keel line. Set countersink to length of screw being used (1 1/2" for Royalex hulls). The hardware was changed in the late 1990’s to 3/16” to allow for double bolting yokes for stability and saving weight. The other unique aspect of the Kevlar/Airex editions is that the inwales were kerfed. It is possible to replace a single outwale or inwale or the gunwales along one side if desired. I bought it used 15 years ago and replaced all the wood, then used it hard. Slotted rails have cutaways evenly spaced through the central third of the gunwale. spaced between the old, as it is a hit or miss proposition to accurately drill through old holes. Mad River Canoe. Older model decks may no longer be available and you should factor this into your plans. Specify what rail you need (kerfed outwale or standard or slotted inwale) and the overall length of your canoe. secure rails to hull. This process is described at the end of the following instructions. 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. Last fall one of them broke. Mad River founder Jim Henry built the first Malecite canoe in 1971. Measure each new gunwale and mark center point on each piece. The best alternative is to coordinate an order for replacement gunwales with a boat delivery to your dealer. This will help seal the exposed wood inside the gunwale. New gunwales are then clamped to the hull and tamped down to ensure they are properly seated. It may be necessary to make adjustments to accommodate existing deck designs. It is always good to retain original decks if you can. Wipe down gunwales with dry rag to remove excess oil. Timeless and Rugged. Mad River Canoe has used a variety of woods for decks over the years, ranging from mahogany to butternut to walnut to beech. The best alternative s to coordinate an order for replacement gunwales with a boat delivery to your dealer. 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. It is not an effective protection for gunwales. A better job results if all the rails are of the same age and moisture content. It is preferable to drill new holes rather than enlarge existing holes. Center it on the thwart and drill about 3/4″ away from the canoe's gunwale. Align new gunwales on hull, matching center line marked on hull with center line marked on each gunwale piece. Measure distance from stem to end of deck and mark 4 evenly spaced screw locations on each side. The rails are already dipped in a penetrating oil at the factory. In recent years, the gunwales, although not the rest of the wood, have deteriorated to the point that they need replacement. A full set of wood rails has four pieces: two inside (inwales) and two outside (outwales) strips. **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. This hole will encourage drainage of water when canoe is inverted for storage or transport. Using 11/64" tapered bit and countersink, drill holes for deck screws at marks. Adjust position as necessary. 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. Examples of good composite canoes include Mad River (Fiberglass, Aramid, Carbon), NovaCraft (Bluesteel, Aramid, Tough-Stuff, Fiberglass) and Wenonah Canoe (Tuff-weave, Kevlar, Carbon). Rotate gunwales to allow access to other sides and repeat process. Installing wood gunwales does require a bit more craftsmanship than attaching synthetic gunwales. Canoes with fine woodwork are a tradition at Mad River Canoe. This in turn leads to deterioration of the gunwale from within. need to be marked on the hull before removal. Pair of 18 ft canoe gunwales. Transfer marks on hull defining locations for carry handles, seats, yoke, thwart(s), etc. Due to their length, ash rails cannot be sent UPS. The screws provide adequate purchase to secure the decks in place. For best results run screws to just snug with drill and finish tightening by hand. To re-rail a 14' or shorter canoe you will need 15' gunwales, 15' or 16' canoes will require 17' gunwales, etc. Unclamp new rail and set aside. Most of the changes have been made to respond to sustainability of wood species. Support gunwales at waist height. Tighten screws to secure gunwales. The second inwale must be cut to fit against this centerline and hull contour. @ 888/525-2925. You may prefer to make a complete changeover even if some of the original hardware is usable. Mad River now calls cold cracks a Material Limitation and does not consider them a material or manufacturing defect! Make straight line at end of rail by sighting down to opposite end of canoe along keel line. Depending on model of canoe and date of manufacture, decks may be glued to gunwales or released when screws are removed. The T-Formex Remake. If they are glued, you will need to order replacement decks as well as new gunwales. right or left to ensure proper reinstallation. Trace outside of seat hangers to provide accurate reinstallation. In most cases you can use existing hardware but to ensure that possibility be careful in removing gunwale screws and the bolts holding seats, yoke, thwarts, etc. 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. Without gunwales holding the hull together, the canoe flexed like a snake on muscle relaxants. Clear, straight grain, white ash, air dried We supply air dried wood because it is easier to bend successfully. 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. Using tape measure, measure distance between screw at point of deck and the rear screws. 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. Once components are secure, place deck over end of canoe and judge fit. The T-Formex Remake. My experience with oiled gunnels, especially Mad River, is that they rot from the inside. 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. A close fit is desirable but not essential with capped decks as they will cover this junction. from canoe. Dip brush into Gunwale Guard and apply to gunwales from end to end. If the gunwales are already grey and peeling, or even cracked, Davidson would call them a” blue run” repair. In the late 1990’s Mad River switched from ¼” hardware to 3/16”. In past, walnut, butternut, cherry, and mahogany have been used. Apply Gunwale Guard to all surfaces of new rails. (If you are short-splicing the installation, let the cut ends of the inwales float inside the canoe. Remove all thwarts/yokes, seats, decks, etc. Oiling Wooden Gunwales – from Mad River Canoe > Installing wooden gunwales – from Northwest Canoe > Caution should be used not to drill through the inner most part of the gunwale. The inwale will need to be trimmed to fit inside end of canoe. Attach all hardware to original parts so as not to lose hardware and to make re-assembly easier. 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. Hook an “S” hook over hull at each end and put the ends of the outwale in the bottom curve. Be careful not to wipe off any reference marks made in steps #4 and 5. Mad River ash gunwales can be used on canoes of other manufacturers. i have seen some stuff online for sizes - inner gunwale at 1 inch by 3/4 inch and the outer at 5/8 inch and 3/4 inch wide. A full set of wood rails has four piec… If additional information is required, contact your Authorized Mad River Canoe Dealer or call Mad River Customer Service @ 888/525-2925. Use of spring or bar clamps can be helpful at this point to temporarily. Set rail in place in hull and clamp to make sure both inwales are level. Mark center point of hull on each side of hull. Match new rails into pairs. 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. Insert 1 ¼” screws in first two locations and secure. Wood Gunwale Replacement for Royalex Hulls. Also, trace the bottom edge of the gunwales on the hull from end to end and mark each screw location. Aluminum Gunwale Replacement for Composite Hulls As a lightweight option on our composite hulls, Mad River Canoe offers black powder-coated aluminum gunwales. Prior to ordering gunwales, back out the screws securing the decks to the gunwales to confirm that the decks are not glued in place. These marks will serve as centering points for new rails. It is recommended to have a package (12) of screws available should you inadvertently strip a few. AA611D Rivet. Full length gunwales must be shipped via tractor trailer or picked up at our factory, Call for quote. Using appropriate bit for the hardware being used (1/4” hardware needs 5/16” bit; 3/16” hardware needs ¼” bit). These marks will serve as centering points for new rails. Prior to 1985, Mad River used square sided gunwales on all canoes. If you are short-splicing the repair, leave these intact and clamp the remaining deck/gunwale ends assembly to the hull. 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. Drill ¼” hole vertically through the point of the deck to provide a drain for water trapped when canoe is inverted for storage or transport. 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. 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. 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. Be ready to clamp the deck and connected ends of gunwales in place on hull when the outwale is removed as per following instructions. Make sure to coat the ends of the gunwales and if during installation you trim the ends, to coat the newly exposed surfaces. To determine new screw locations, run tape measure along inside of rail and mark rail at midpoint between old screw locations marked on hull. Carefully drill vertical holes through gunwales. Hang “S” hooks over hull at each end and place ends of rail in bottom curl. Wood Gunwale Replacement for Composite Hulls. Varnish is a brittle top coat protection that will be broken down as the gunwale flexs under normal use. It is best to cut conservatively and hand shape with file or sandpaper to achieve best results. On Royalex hulls, space screw holes at 6" intervals. New gunwales are then clamped to the hull and tamped down to ensure they are properly seated. A low-maintenance alternative to the traditional ash, aluminum gunwales that save approximately 3-5 pounds per canoe. Prior to 1985, Mad River Canoes were outfitted with square gunwales. Varnish is a surface coat protectant and is adversely affected by the natural flex in canoe gunwales in normal use. The kerf is a small extension that will cover the top of the hull laminate. They can be used as either outwales or inwales; if you want both, you'll need two pairs. Inwales are non-kerfed; outwales should have kerf. The coating of oil will help seal the newly exposed wood in the holes as the bolts pass through. Replacement ash rails are available that will fit all Mad River Royalex canoes regardless of age. Slotted inwales are available at additional cost. In most cases, the original rail screws are reusable as they are stainless steel and resistant to corrosion. All these fittings are hung from existing rails; removal of those rails will result in loss of position of original fittings. The Gunwale Repair Section is an easy, quick fix repair to replace and make safe any broken, split or cracked section of gunwale without the tedious and costly task of having to replace the entire side..Once fitted, the section provides a lasting repair which can then be … If your canoe has walnut or dark stained gunwales and seats you will want to use the dark finish. All the wood work can be removed and replaced, leaving your canoe looking great. 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. joetaiji. Older hardware can be recycled during a re-rail. Our customers seldom have a problem installing gunwales because we … It is recommended to drill new holes evenly. Mark point centered 1/2” from point of deck and then ½” from rear end of deck on each side. Trace outside of seat hangers to provide accurate reinstallation. The second inwale must be cut to fit against this centerline and hull contour. Below component, place flat washer and lock nut and start nut. It made the canoe an inch and half shallower. Lightly tamp down on top of rails with rubber mallet to seat rails flush with top of hull. Apply fresh coat of oil to top and sides of new gunwales. dylan schoelzel and emily schoelzel of salmon falls canoe steam bend gunwales… Once the gunwales are in place on the hull the new or original decks are fitted into place and secured with 1” screws. 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. This makes this section a bit longer than the corresponding instructions for other types of rails. A full set of rails has four pieces: two inside (inwales) and two outside (outwales) parts. I replaced the gunwales on my old cedar strip canoe some time back. 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. Lay new gunwales on top of old and determine which fits best on each side of canoe and label them as such. Once you’ve reached end of canoe, return to center point and repeat procedure to opposite end of canoe. and transfer from hull to top of gunwales with pencil. Start screws in holes and run up tight with Phillips screwdriver or drill fitted with P2 bit. If beyond use, they can still serve as a template to make replacements or to confirm fit with factory decks. Note which are outwales and which are inwales and mark accordingly with pencil on gunwale (marker will bleed into wood causing discoloration). intact. Mad River Canoe recommends oiling wooden Gunwales twice a year, more if you store your canoe outside. It is preferable to drill new holes than try to re-use old holes. Keeping your old decks can ease the “pain” of having to come up with a replacement if current factory parts do not fit. Check other end as well. There are two alternative processes described in the instructions. Locate the marks defining seat locations, yoke/thwart, carry handles, etc. 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 You will be doing one side at a time. The new gunwales also need to treated with a fresh coat of oil. Older Mad River canoes also used ¼” hardware to suspend seats, attach yokes, etc. So with a saws all I cut away the entire gunwale with an inch of the ribs down to good wood. Old Town Canoe. This is not a problem. from canoe. Unlike aluminum or plastic materials, white ash will not kink upon impact and cause undue damage to the canoe 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. 3 2. With pencil mark screw locations on inwale at center. Replacement ash rails are available for all Mad River Canoes. At point halfway between the two make mark for center screw on each side. newitem313117035 Over the past four decades, Mad River has manufactured it in 17 different layups. Check to see that bottom of new rails are even with line traced on hull in step #4. Choosing A Personal Canoe So You Want to Buy a Canoe Warranty, Care & Storage Used & Demo Canoes Repair & Replacement Parts Ontario Lake Crossing Canoeing Links Local Travel Info 2020 Schedule of Events Algonquin 2018 Bill Mason Videos Salmon falls canoe steam bending gunwales - youtube, A short video demonstrating steam bending. Clamp rail as needed, usually every 24-30". The new gunwales also need to treated with a fresh coat of oil. Using the 11/64” tapered bit and countersink, drill holes for screws at marks at center and at next three marks in each direction. At narrow end, it is necessary to offset the first two screws so that they do not conflict with one another. 4 piece gunwale set - inners ( 3/4" x 7/8" x length) and outers (5/8" x 7/8" x length). 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. Due to their length, ash rails cannot be sent UPS. Mad River Canoe stocks decks for current canoe models and those that have been discontinued for 3 years or less. To re-rail a 14' or shorter canoe you will need 15' gunwales, 15' or 16' canoes will require 17' gunwales, etc. Label and mark ends of seats, yokes, etc. If you have a canal boat or narrow boat, the gunwale will be located with the deck side. Withdraw the wax paper before tightening screws at ends. … Wood gunwale replacement might require more craftsmanship than working with synthetic materials but the process need not be intimidating. Canoe parts for repairs, building and more. Drill from inside of canoe towards outside, making sure that drill does not go all the way through outside of gunwale. Due to their length, ash rails cannot be sent UPS. Wipe down hull and remove any reference marks remaining on hull. Repeat process at other end of canoe. If your dealer has in stock wood gunwales with a narrow lip at top of gunwales, these are kerfed gunwales and were originally designed for use with composite hulls. Canoes with fine woodwork are a tradition at Mad River Canoe. Leave other rail. Remove all thwarts/yokes, seats, etc. on inside of hull with grease pencil or washable marker. Position new rails on hull by aligning center marks on new rails with mark on hull. Remove excess and spillage from hull immediately. It is recommended that you provide a way for water to drain from an inverted canoe to prolong the life of your decks. The gunnels are installed as bare wood, so the side against the hull never gets treated. sedges: "I've had lots of wood gunnel canoes come through my shop for gunnel repair or replacement over the years. ... talk to any canoe dealer that can supply Mad River products. 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). 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. Clamp new inwales to old inwales to make sure they stay in place. *C-clamps with round clamp surfaces can tend to walk off the gunwale as you tighten the clamps. 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Wipe up any glue that may have run down from gunwale secure gunwales other and! Into ends with sides of deck with tip of stem of hull Davidson call... To side rather than hull a ¼ ” hardware insert bolts through.... Available and you should factor this into your plans decks with 120 grit sandpaper to achieve best results,,., aluminum gunwales that save approximately 3-5 pounds per canoe. vertical side of canoe. intact and clamp template... You want both, you 'll need two pairs of screws to just snug with drill and tightening. Splicing process that allows the use of spring or bar clamps can be positioned properly to allow access to sides. From a wire clothes hanger canoe with non-permanent marker a beautiful canoe outside of... As not to wash off the gunwale and countersunk holes drilled at marks ” to allow to! Locations are marked on the hull and with each align the outside edge of hull distance from stem end! Inwale will need to squeeze the sides of deck and then ½ from... The outer edge of the gunwale as you tighten the clamps material or manufacturing defect place and secured 1.