Team at JBK are proud to announce the Molding Process for the Mega
Proton High Performance Surf Kayak is now complete and is available for
order here in Australia. For the Past 10 Years JBK has manufactured Mega Surf Kayaks
under license here in Australia and we are proud to produce these
beautiful craft to avid Kayak Surfers both here and in New Zealand.
The Mega Proton High Performance Surf Kayak
I would share some photos of the molding process that produces
composite kayaks, and highlight the need for extremely high quality
patterns to produce the molds that result in the beautiful quality craft
that Mega Kayaks International are renowned for.
begin with a high quality pattern that is air freighted to us from
Malcolm Pearcey of Mega International in the UK. Malcolm's attention to
detail is impeccable and provides an insight into the Designer who has
since 1991, lead the world in Surf Kayak Design and Innovation.
undergoes extensive testing by Reputable Kayakers in Europe and the UK
prior to us making the decision to introduce to Australia. We are
looking for Surf Kayaks that suit the Developing Paddler Scene in
Australia and well suited to our typical wave types and experience
Upon it's arrival,
the plug is prepared with a flange on it's seam to enable future vacuum
infusion molding and to add additional strength and durability to the
Mold. The Flange is fashioned from layers of Fibreglass that is held in
place on the Pattern and a radius of Molding Clay neatly fills the small
gap and is meticulously prepared to ensure a slightly rounded edge. The
Plug is then given a series of polishes to produce a perfect gloss
finish that will reflect the quality of the mold.
It is essential
that a clean environment be kept at all stages of the process to ensure
the Pattern is dust free and that no imperfections are introduced,
including dust, lint and insects that may be attracted to the highly lit
After five coats
of High Temperature Release Wax the pattern is now ready to be coated in
a layer of Tooling Gel Coat that will form the surface of the mold. The
Gel Coat is catalysed with a Hardener that sets the Resin to a tacky
layer in about 4 hours and is then ready to accept multiple layers of
Fibreglass Matting and extra composite reinforcement to form a Mold
about 4 to 5 times the thickness of the product to be produced.
The series of
photos shows a process that is completed over several days as subsequent
layers are applied 2 at a time to avoid high exothermic heat and damage
to the plug or mold surface.
Mega Proton Hull from initial Preparation to final Mold.
The same process
is applied to the deck pattern as it is matched on the hull mould to
enable a perfect separating edge and ease of joining. The Patterns are
retained in the mold for a week or so to enable proper curing.
Deck Pattern is matched to the hull and the process repeated to produce
the deck mold. Upon release of the pattern the Mold is polished to a
high finish to produce a superb finish.
The final process
involves removing the pattern from the mold and this is done by
separating the pattern with wedges and gentle and sometimes quite
physical persuasion, ultimately the pattern is removed undamaged
resulting in a perfect female replica of the pattern. Final preparation
before the the first kayak is laid into the mold requires a series of
polishes to increase the luster and maintain a perfect surface for the
I hope this has
provided some insight into the Manufacture of the Mega Product Range,
and the same process is used to form the Molds for all Kayaks that are
constructed of Composite Materials.
Ross Boardman - Director - Jervis Bay Kayak and Paddlesports Co / Mega Surf Kayaks Australia / Seaward Kayaks Australia