Surfski and Kayak Composite Layup Selection Guide.

Composite: combining the typical or essential characteristics of different materials in the making of a boat.

In the 1970s composite kayaks were made of fiberglass which resulted in previously unattainable shapes and strength to weight ratios. Fiberglass is what made the modern sport of sea kayaking possible, with Brittain and the Pacific Northwest of the USA taking the lead. Over the decades, other fabrics such as Kevlar began to be used which resulted in stronger and lighter boats. In the last twenty years, use of carbon fibers and core laminates has made possible even lighter craft for higher performance!

As an example, this video from Stellar Kayaks explores the four layup options used in the construction of their boats. In general, the lighter the boat, the more expensive it will be. This is due to progressively more specialized (and expensive) materials and industrial processes needed to maintain the desired strength and stiffness at a reduced overall weight.

Stellar is a leader in this field and offers the following layups:

Advantage:

This laminate is Soric cored fiberglass with a gelcoat exterior, making is stiffer and lighter than the Sport, but also at a good price point. This laminate has better performance than the Sport, but also similar toughness and ability to absorb some abuse. This is our most popular boat for touring and entry level surf skis for its combination of durability, stiffness, weight and price.

Excel :

This laminate is Kevlar with Nomex Honeycomb core and a gelcoat exterior, making it very stiff and very light. This is a performance laminate designed for those who desire a stiff and fast boat and know how to handle a boat on and off the water. The Nomex core makes for a light and stiff boat, but the impact resistance is much less than that of the Advantage or Sport. If you hit a rock or log or even tie down the boat too tight on unsupported racks, this could result in damage.

Alpha:

This laminate is Carbon with Nomex Honeycomb core and a painted finish, making it extremely stiff and light weight. This is a performance laminate designed for those who desire the stiffest and fastest boat and know how to handle a boat on and off the water. The Nomex core makes for a light and stiff boat, but the impact resistance is much less than that of the Advantage or Sport. If you hit a rock or log or even tie down the boat too tight on unsupported racks, this could result in damage. Secondly, the painted finish is more prone to scratching than the gelcoat finish, so take care to clean the boat well and avoid running it aground when landing to keep the finish pristine.

Multisport:

This laminate is an innovative offering, with a single skin laminate hull made of Carbon & Kevlar, with an EPS Foam stringer, which is flexible and durable, but creates a stiff boat that can take some abuse in the rivers and shallows. Tested in New Zealand, this laminate is at home racing down rivers through the rapids or in the ocean. The Surf Ski Multi-Sport construction comes standard with an over-stern rudder and fittings for an under-stern rudder, as well as a flush mounted Andersen mini-bailer, while the Touring kayak version has the usual features. This laminate is ideal for those who paddle in shallow rivers, lakes or even rocky shorelines where the boat will encounter the bottom from time to time.

Other manufactuirers offer competetive layup options that are similar to Stellar, although the Multisport is unique among the "big" brands in the industry. Apart from the materials, manufacturing processes and facilities also matter.

In the end, it's this which will ultimately determine how a boat will handle, feel and look.