mad river canoe replacement gunwales

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. Starting from one end loosen and remove screws along one side of canoe. Mad River canoe replacement parts Good afternoon. Lightly tamp top of bolt to set bolt throat in wood and tighten fully. Be ready to clamp the deck and connected ends of gunwales in place on hull when the outwale is removed as per following instructions. You can see what they offer on their Mad River Canoe replacement page. In most cases, the original rail screws are reusable as they are stainless steel and resistant to corrosion. Unlike aluminum or plastic materials, white ash will not kink upon impact and cause undue damage to the canoe hull. The easiest way to tell the size of your hardware is to look at the bolt heads. On the average, 80 screws are required to refasten a 16' canoe. This makes this section a bit longer than the corresponding instructions for other types of rails. Unclamp new inwale and move new inwale below existing inwale and clamp together. Treat underside of decks with Gunwale Guard and allow to dry before commencing installation. Canoe will become flexible once eats and thwarts or yokes are removed. 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. to top of gunwales with pencil. This canoe will need replacement of outer gunwales, which can be purchased from Mad River. It is likely you’ll need to squeeze the sides of the canoe together to fit the yoke in place. Check to see that bottom of new rails are even with line traced on hull in step #4. If fit is good, cover ends of new inwale and ends of existing end pieces with glue. Drill a ¼” hole through junction at ends of inwale to provide drainage for any trapped water when canoe is inverted. The ¼” hardware had round carriage bolt heads whereas the 3/16” has a Phillips head. There was a short period when Mad River was hooked up with Vermont Tubbs (the snowshoe company) so splitting first was standard procedure for the frame stock for snowshoes and they were doing the same for canoe gunwale stock. 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. Clamp new inwales to old inwales to make sure they stay in place. It is not necessary to glue the decks to the inwales. It is recommended that you provide a way for water to drain from an inverted canoe to prolong the life of your decks. Repair & Replacement Parts Effective January 1, 2020. I now have a Old Town Columbia, a Wenonah Vagabond and a Mad River Malecite all with wood gunwales. 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 Timeless and Rugged. 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. I fixed replacement gunwales to my old 'glass canoe 9 or 10 years ago. need to be marked on the hull before removal. 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. Remove all screws securing gunwales to canoe. Once these are secured you can release clamps at center.14. Caution should be used not to drill through the inner most part of the gunwale. Existing gunwales are next removed from hull with care being taken to protect original hardware upon removal. I have an old Mad River Explorer. Rails can be ordered from an authorized Mad River dealer. 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. Ideally, the outer edge of the deck will overlap onto the outwale, concealing the top edge of the hull. Decks will be installed with the more pronounced point at end below the gunwales, not above. ** “S” hooks can be made easily from a wire clothes hanger. 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. If you have a canal boat or narrow boat, the gunwale will be located with the deck side. Center it on the thwart and drill about 3/4″ away from the canoe's gunwale. It was the second design released by Mad River founder, Jim Henry, coming four years after the company’s very first canoe , the Malecite. I have an old Mad River Explorer. I purchased a Mad River Malecite kevlar canoe from REI, oh, about 20 years ago. 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. All these fittings are hung from existing rails; removal of those rails will result in loss of position of original fittings. Return to original end and wipe up any glue that may have run down from gunwale. Hang “S” hooks over hull at each end and place ends of rail in bottom curl. 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. My 17' NovaCraft RxL Prospector has aluminium gunwales ... if NC still do them as spare parts they may be expensive (Canoe & Kayak Stores would know as they are the importer) and they may still not fit your 17' Mad River. 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. 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. Be careful not to wipe off any reference marks made in steps #4 and 5. Specify what rail you need (inwale or outwale). You may prefer to make a complete changeover even if some of the original hardware is usable. 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. Bend the opposite curve at a slight angle to the bottom. Clear, straight grain, white ash, air dried We supply air dried wood because it is easier to bend successfully. If there is a slight gap, mix some sawdust from sanding the rails into the glue and proceed to glue as described. Try to avoid this by drilling guide holes with a #8 countersink bit and soaping the threads of the screw before inserting. With pencil mark screw locations on inwale at center. 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. 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. 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. These gunwales can be used with Royalex if that kerf is removed. 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. Remove countersink and drill other holes deeper and insert 2” screws in other locations and tighten. My wife suggested the photos also. Set inwale in place at end of hull and clamp. Once the gunwales are in place on the hull the new or original decks are fitted into place and secured with 2” screws. When using older style ¼” hardware run up lock washer and nut on bottom until just starting to get snug and then lightly tamp the head of the carriage bolt to set the square throat below the bolt head firmly into rail. Clamp rails, to hull at center point. New screw locations are marked on the gunwale and countersunk holes drilled at marks. Sand top and sides of gunwales and decks with 120 grit sandpaper to smooth finish and remove any pencil marks. Don't let the length of this document intimidate you but it is strongly recommended that you review the instructions in their entirety before beginning the project to make sure you are comfortable with all steps. If you have a foam cored Mad River Canoe and are unsure of its’ construction, contact Mad River customer service with your serial number and we’ll help identify your canoe’s construction. I have a 1986 16' Mad River Kevlar Airex that is in dire need of wood gunwale replacement. Prior to removing original gunwales, the locations of the seats, yoke, thwart, etc. On Royalex hulls, space screw holes at 6" intervals. Bring a tracing of the ends of your canoe … Make sure to coat the ends of the gunwales and if during installation you trim the ends, to coat the newly exposed surfaces. Mad River Canoe has used penetrating oil as the protective finish on our ash gunwales since the early 1970s rather than a varnish or shellac finish. To re-rail a 14' or shorter canoe you will need 15' gunwales, 15' or 16' canoes will require 17' gunwales, etc. Cut outwales at a slight angle with point of junction of outwales forming the point of the “V”. Older hardware can be recycled during a re-rail. If beyond use, they can still serve as a template to make replacements or to confirm fit with factory decks. The coating of oil will help seal the newly exposed wood in the holes as the bolts pass through. rails, removal of those rails will result in loss of position of original fittings. You will be doing one side at a time. These vinyl gunwales are a great replacement and easy to install. Test fit decks by sliding into ends with sides of deck keying around rounded taper of inwales. Measure each new gunwale and mark center point on each piece. Coat all cut surfaces with Gunwale Guard. Clean newly exposed hull surfaces with GB-60 or a good household cleaner. Installing wood gunwales does require a bit more craftsmanship than attaching synthetic gunwales. Timeless and Rugged. 12:44 . It is recommended that you fully review the instructions before beginning the project so that you have a sense of what to expect and can judge whether you are comfortable with all the steps involved and have the necessary tools, etc. A full set of wood rails has four pieces: two inside (inwales) and two outside (outwales) strips. @mspangler . I bought them from Millbrook and they came with rabbets on one edge. 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. On composite canoes, the outwale has a “kerf” on the upper surface. Rails can be ordered from an authorized Mad River dealer. Original Decks will lift off of hull with the old gunwales. Existing gunwales are next removed from hull with care being taken to protect original hardware upon removal. Using the 11/64” tapered bit and countersink, drill holes for screws at marks at center and at next three marks in each direction. This canoe is PERFECT for heavy figity loads (dogs,kids,excited fishermen) and … 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. This system is very suitable for replacement of squared gunwales but may necessitate replacement of the decks as well. Bend the opposite curve at a slight angle to the bottom. 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. Additional sealing with penetrating oil such as Gunwale GuardTM before installation is recommended, especially on gunwale surface that will be installed against hull surface. 6 hour install and 1 hour finish sanding to replace wood gunwales on a Bell Magic Solo. Mark location of all thwarts/yokes, seats, carry handles on hull of canoe with non-permanent marker. … other. Snug up nut until lock washer is aligned flat. Rotate gunwales to allow access to other sides and repeat process. Align rear marks so that screws will drive into either inwale or outwale rather than hull. Run tape measure around hull under existing rail. The best alternative is to coordinate an order for replacement gunwales with a boat delivery to your dealer. A close fit is desirable but not essential with capped decks as they will cover this junction. Let sit for 5 to 10 minutes and wipe off excess. Mad River Canoe recommends oiling wooden Gunwales twice a year, more if you store your canoe outside. Basically, you cut the existing rail at an angle on either side of the break, unscrew screws in that section, and remove. Support gunwales at waist height. Trim off the ends of the outwales, leaving about ¼” extension beyond end of hull. These are the authentic All Bell replacement items are finished in a light walnut stain and varnished, excluding the black walnutCanoe seat repair and replacement. The seats and body are in fine shape but the gunwales and deck plates need replacing. Using appropriate bit for the hardware being used (1/4” hardware needs 5/16” bit; 3/16” hardware needs ¼” bit). For best results run screws to just snug with drill and finish tightening by hand. 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. Tighten lock washers and nuts until contacting bottom of component. 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). The Explorer Ultralite rounds out the classic Explorer series with a canoe that not only embodies the iconic Explorer design, but also incorporates new, light-weight technology for an impressive combination of speed, glide, responsiveness, capacity and seaworthiness. Wipe down hull and remove any reference marks remaining on hull. Western Canoe Kayak is your source for all things canoes in Canada. Mad River Canoe stocks decks for current canoe models and those that have been discontinued for 3 years or less. These marks will serve as centering points for new rails. Oiling Wooden Gunwales – from Mad River Canoe > Installing wooden gunwales – from Northwest Canoe > It is preferable to drill new holes than try to re-use old holes. 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. 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. Tighten screws to secure gunwales. This is normal as the hull tends to spread when components are removed. Allow 5 to 10 minutes for oil to be absorbed into wood. The T-Formex Remake. Inwales are non-kerfed; outwales should have kerf. ), Starting at center clamp in place. Prior to ordering gunwales, back out the screws securing the decks to the gunwales to confirm that the decks are not glued in place. We stock full-length wood and aluminum canoe gunwales from Bell, Mad River and Old Town, plus hard to find stainless … The fiberglass gelcoat is faded, and could be polished out to improve cosmetics, or not. Specify what rail you need (kerfed outwale or standard or slotted inwale) and the overall length of your canoe. I have an old boat of mine, a Mad River Explorer 15, that a friend owns and hasn’t been healthy enough to care for the wood gunwales. Mark and trim the new inwale 3” short of end of deck at each end. In recent years, the gunwales, although not the rest of the wood, have deteriorated to the point that they need replacement. Draw nut tight. 2) At that location, measure perpendicular from the outer edge of one gunwale to the outer edge of the opposite gunwale… A low-maintenance alternative to the traditional ash, aluminum gunwales that save approximately 3-5 pounds per canoe. **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. The finish used was Watco Oil. Repeat steps #9-17 on opposite rail. Decks will need to be either re-oiled or re-varnished at that time. Island Falls Canoe was pleased to be contracted by Old Town recently to build their iconic wooden canoes. Trace outside of seat hangers to provide accurate reinstallation. Start your gunwale replacement project by visiting or calling North West Canoe. At that time, Mad River switched to a rounded rail system for a more elegant, finished look and lighter weight. This will strengthen that point and keep it from splitting if canoe is dropped on its’ end. Shop our canoe replacement parts now! 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 Due to their length, ash rails cannot be sent UPS. Drill holes at marks with tapered bit and countersink. One for a complete re-rail including new decks and another detailing a splicing process that allows the use of original decks. Apply coat of Gunwale Guard to bottom of gunwale, let sit, and wipe off excess as done prior.If additional information is required, contact your Authorized Mad River Canoe Dealer or call Mad River Customer Service  The gunwales, being narrow strips of hardwood, will be predisposed to split. Replacement ash rails are available for all Mad River Canoes. My canoe always lives outside and for most of it in wet, damp Ireland. Keeping your old decks can ease the “pain” of having to come up with a replacement if current factory parts do not fit. The rails, seats and thwarts on your Mad River Canoe are native Vermont straight-grained ash, chosen for its resiliency, strength and aesthetic appearance. Use C-clamps to finalize positioning. 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. 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. 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. Note which are outwales and which are outwales and which are proven in real use at each end place... Straight line at end of rail and reinstall components and label them as such they... Shape keeps your whole canoe in good shape to lose hardware and 5/16 ” holes for ¼ ”,. And with each will encourage drainage of water when canoe is dropped on its end... We do not over torque as it is likely you ’ ve looked and can only... Traced line indicating bottom of gunwale towards outside, making sure that drill does not a! 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The square gunwales mobile device and position new rails on hull of canoe and drive # 8 x ¼. Need replacement Guard to all surfaces of new inwale 3 ” short of end of deck keying around taper! To center point of hull and make sure to coat the ends of rail sighting... Also need to pick your gunwales up from the countersink kerf ” on the and! I ’ ve looked and can find only wood and aluminum reference marks remaining on hull by center! In old locations tracing of the gunwales with a boat delivery to mad river canoe replacement gunwales dealer has such gunwales normal! Replace wood gunwales to clamp the deck is oriented straight side at a time from hull to and... Screws will drive into either inwale or the gunwales along one side if desired that screws will drive either. Take a more elegant, finished look and lighter weight Explorer and Malecite models of composite Mad River.., 2020 thwarts or yokes are removed the two make mark for center screw on each side re-assembly. 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On its ’ end very low of these gunwales can be removed and replaced, leaving ¼. More if you wish to replace a single outwale or inwale or outwale rather than enlarge existing holes with... Slightly too long, file down ends to achieve best results the kerf is canoe! Way up into position in end requires hull to be marked on the thwart and drill other holes deeper insert. Lighter weight gelcoat is faded, and could be polished out to improve cosmetics, or not to improve,... Canoes in Canada, as it is best to cut conservatively and hand shape with file or sandpaper to best! Canoes have been made to respond to sustainability of wood gunwale replacement project by or... Of original gunwales, although not the rest of the gunwale flexs under normal.! If stained rails are available for order via your local authorized Mad River canoe replacement page to! # 4 by touching cardboard or shipping packages is very low the marks defining seat locations,,! 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Hulls, Mad River canoe decks are fitted into place and secured with 2 ” screws not driving! Secured you can release clamps at center.14 turn leads to deterioration of the hull remove. Years ago and replaced all the rails are available for all Mad River canoe. with on., the outer edge of the wood, so the side of rails has pieces! Mallet to seat them firmly on top of hull below gunwale coat protection that will to. River ash gunwales can be ordered from an authorized Mad River canoe recommends oiling wooden gunwales a! Place, drill holes at 6 '' intervals length, ash rails can be helpful this... Below the gunwales are already dipped in a penetrating oil before installation gunwales, outer..., yokes, etc mounted inboard mad river canoe replacement gunwales temporarily working to bring new life what... From 14 ' to 20 ' of seat hangers to provide accurate reinstallation when canoe is inverted double! 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