Mad River Canoe has used a variety of woods for decks over the years, ranging from mahogany to butternut to walnut to beech. intact. You can use your original hardware or convert your canoe to current standards. It is recommended to have a package (12) of screws available should you inadvertently strip a few. (Editors note: Drilling holes at the end of crack… Flip canoe over onto gunwales and mix up some glue with the saved sawdust and use mixture to fill the “V” shaped void at each end of canoe where outwales meet. Wipe clean and apply Gunwale Guard as described above. Clamp rails, to hull at center point. In most cases, the original rail screws are reusable as they are stainless steel and resistant to corrosion. Remove the “S” hooks. 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. On 3/16” hardware, place dimpled finish washer over bolt before inserting into gunwale and secure at bottom with flat washer and locknut. Also trace line of bottom of rail on hull. 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. 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). This is not a problem. New screw locations are marked on the gunwale and countersunk holes drilled at marks. Trim off the ends of the outwales, leaving about ¼” extension beyond end of hull. Below component, place flat washer and lock nut and start nut. The easiest way to tell the size of your hardware is to look at the bolt heads. *C-clamps with round clamp surfaces can tend to walk off the gunwale as you tighten the clamps. Center it on the thwart and drill about 3/4″ away from the canoe's gunwale. dylan schoelzel and emily schoelzel of salmon falls canoe steam bend gunwales… A low-maintenance alternative to the traditional ash, aluminum gunwales that save approximately 3-5 pounds per canoe. 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. Full length gunwales must be shipped via tractor trailer or picked up at our factory, Call for quote. Replace Mad River gunwale, seats, carry yoke? Repeat steps above to install opposite rail. Wipe down gunwales with dry rag to remove excess oil. Hang the top curve over the side of the hull and put the outwale in the bottom curve. Replacement one piece aluminum gunwales are available for Mad River Explorer and Malecite models of composite Mad River Canoes. You will be doing one side at a time. Angle should run so that end against hull will be closest to deck. @ 888/525-2925. It is recommended to have a package (12) of screws available should you inadvertently strip a few. $0.65. Last fall one of them broke. I did a Mad River Malecite and a Perception HD-1 and an Old Town Penobscot this way. A better job results if all the rails are of the same age and moisture content. Wood Gunwale Replacement for Royalex Hulls. Trace outside of seat hangers to provide accurate reinstallation. Set rail in place in hull and clamp to make sure both inwales are level. A full set of wood rails has four piec… The best alternative is to coordinate an order for replacement gunwales with a boat delivery to your dealer. and transfer from hull to top of gunwales with pencil. 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. All the wood work can be removed and replaced, leaving your canoe looking great. Our customers seldom have a problem installing gunwales because we supply air dried wood. Be careful not to wipe off any reference marks made in steps #4 and 5. Remove the screws located approximately 12" from end of decks. These gunwales can be used with Royalex if that kerf is removed. Tighten hardware firmly but do not over torque as it is possible to sheer off stainless steel if over tightened. The hardware is durable stainless steel but the heads or threads can be stripped during removal. Let dry. 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. Pair of 18 ft canoe gunwales. Replacement rails are finished natural. Run tape measure around hull under existing rail. Start screws in holes and run up tight with Phillips screwdriver or drill fitted with P2 bit. Coat all cut surfaces with Gunwale Guard. You will be doing one side at a time. 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. So please can anyone advise aluminium replacement parts as it will be kept outside for long periods. 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. Specify what rail you need (inwale or outwale). Reposition decks on canoe and drive #8 x 1” Phillips head screws into gunwales below decks to secure decks. Timeless and Rugged. … The first inwale installed MUST be cut to fit flush against hull contour as well as along a center line along the "keel" line of the canoe. So with a saws all I cut away the entire gunwale with an inch of the ribs down to good wood. All above materials are available for order via your local Authorized Mad River Canoe Dealer. Replacement gunwales will need to be treated with Gunwale Guard or equivalent penetrating oil before installation. Due to the length of these gunwales, they must ship via freight carrier on a tractor trailer. Attach all hardware to original parts so as not to lose hardware and to make re-assembly easier. The T-Formex Remake. 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. Hardwood is the preferred material. **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. 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. Check other end as well. If fit is good, cover ends of new inwale and ends of existing end pieces with glue. Rotate gunwales to allow access to other sides and repeat process. 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. At narrow end, it is necessary to offset the first two screws so that they do not conflict with one another. These marks will serve as centering points for new rails. Mad River now calls cold cracks a Material Limitation and does not consider them a material or manufacturing defect! The best alternative is to coordinate an order for replacement gunwales with a boat delivery to your dealer. The inwale will need to be trimmed to fit inside end of canoe. Seats, yoke, thwart or carry handles are then reinstalled at original locatons and finally a coat of oil is applied for maximum protection. They can be used as either outwales or inwales; if you want both, you'll need two pairs. Remove excess and spillage from hull immediately. The screws that connect the decks to the gunwales are 2” or 2 ½” long and should be removed slowly if you are doing a complete rerail. Canoes with fine woodwork are a tradition at Mad River Canoe. 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. On Royalex hulls, space screw holes at 6" intervals. other. Mad River Canoe Cane Seat Stained 32." Older hardware can be recycled during a re-rail. Prior to removing original gunwales, the locations of the seats, yoke, thwart, etc. This makes this section a bit longer than the corresponding instructions for other types of rails. One for a complete re-rail including new decks and another detailing a splicing process that allows the use of original decks. from canoe. It is always good to retain original decks if you can. 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. Repeat procedure for opposite end. Holding the rail in place over stem of canoe, trace contour of stem of canoe onto rail with pencil so that rail will conform to hull shape. Oak Orchard only recommends canoe models which are proven in real use. In most cases, the original rail screws are reusable as they are stainless steel and resistant to corrosion. Wipe down gunwales with dry rag to remove excess oil. Withdraw the wax paper before tightening screws at ends. 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. Care must be taken to sand down the exposed top edge of the hull laminate between the gunwales as this can be sharp and a bit ragged. Transfer marks on hull defining locations for carry handles, seats, yoke, thwart(s), etc. naturally i really dont want to spend that much on them. Drill holes at marks with tapered bit and countersink. Current Mad River Canoe decks are made of beech. Without gunwales holding the hull together, the canoe flexed like a snake on muscle relaxants. @mspangler . Mad River founder Jim Henry built the first Malecite canoe in 1971. You may have to fabricate your own deck. When fitting the ends of inwale inside stem, trace not only shape of stem of hull but also mark where other inwale will contact and cut accordingly. Prior to removing original gunwales, the locations of the seats, yoke, thwart, etc. The Malecite, a 16.5-foot … Due to their length, ash rails cannot be sent UPS. Most of the changes have been made to respond to sustainability of wood species. 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. 4 piece gunwale set - 3/4" x 7/8" x length of canoe Clear, straight grain, white ash, air dried. This in turn leads to deterioration of the gunwale from within. The kerf is a small extension that will cover the top of the hull laminate. Adjust position as necessary. 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. Apply Gunwale Guard to all surfaces of new rails. It is possible to replace a single outwale or inwale or the gunwales along one side if desired. 4 piece gunwale set - inners ( 3/4" x 7/8" x length) and outers (5/8" x 7/8" x length). The length of a canoe is usually measured down the center along the keel line. To re-rail a 14' or shorter canoe you will need 15' gunwales, 15' or 16' canoes will require 17' gunwales, etc. In past, walnut, butternut, cherry, and mahogany have been used. The rails are already dipped in a penetrating oil at the factory. Prior to ordering gunwales, back out the screws securing the decks to the gunwales to confirm that the decks are not glued in place. If re-rail job will include complete replacement of inset decks, care must be taken to ensure proper fitting of the ends of the inwales. Support gunwales at waist height. My experience with oiled gunnels, especially Mad River, is that they rot from the inside. 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. 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. Drill from inside of canoe towards outside, making sure that drill does not go all the way through outside of gunwale. 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 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 For best results, however, it is recommended that you replace gunwales as a complete set. 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. Our customers seldom have a problem installing gunwales because we … Replacement rails are available only in the rounded format. Clamp as needed to maintain position. It is recommended to drill new holes evenly. Remove countersink and drill other holes deeper and insert 2” screws in other locations and tighten. Royalex Hull. 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. 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. Mark point on rail where deck ends. secure rails to hull. We stock full-length wood and aluminum canoe gunwales from Bell, Mad River and Old Town, plus hard to find stainless hardware. Once components are secure, place deck over end of canoe and judge fit. Insert screws into holes and tighten. Remove all thwarts/yokes, seats, etc. rails, removal of those rails will result in loss of position of original fittings. It looks like you may need to call to talk to them about the correct gunwales for your canoe. Due to their length, ash rails cannot be sent UPS. 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. Mark center point on each side of hull below gunwale. Dip brush into Gunwale Guard and apply to gunwales from end to end. Mark point centered 1/2” from point of deck and then ½” from rear end of deck on each side. Mad River Canoe does not recommend the use of varnish to protect gunwales. Return to original end and wipe up any glue that may have run down from gunwale. Older model decks may no longer be available and you should factor this into your plans. Mad River debuted the Explorer in 1975 in fiberglass. It is recommended that you provide a way for water to drain from an inverted canoe to prolong the life of your decks. Clear, straight grain, white ash, air dried We supply air dried wood because it is easier to bend successfully. 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. Slotted rails have cutaways evenly spaced through the central third of the gunwale. 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 … This system is very suitable for replacement of squared gunwales but may necessitate replacement of the decks as well. On the average, 80 screws are required to refasten a 16' canoe. Bend the opposite curve at a slight angle to the bottom. A pair of canoe gunwales 18 ft long in pieces with pre-cut scarf joints for joining them to their finished 16 ft length. Working towards one end, align rails even with top of hull. The hardware was changed in the late 1990’s to 3/16” to allow for double bolting yokes for stability and saving weight. How to Make Wooden Canoe Gunwales 1. Wood gunwale replacement might require more craftsmanship than working with synthetic materials but the process need not be intimidating. Align the outside rails along the outside edge of the hull. 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. This process is described at the end of the following instructions. Canoe thwart replacement Canoe thwart replacement Manufacturers of canoe parts and accessories. Canoe will become flexible once seats and thwarts or yokes are removed. Drill a ¼” hole through junction at ends of inwale to provide drainage for any trapped water when canoe is inverted. available in lengths from 14' to 20'. If not drilled precisely on target the old holes will be enlarged and result in a loose gunwale installation. 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. Rails can be ordered from an authorized Mad River dealer. Salmon falls canoe steam bending gunwales - youtube, A short video demonstrating steam bending. Skid plate kits, composite repair kits, fiberglass, epoxy resin, gunwales... Health officials state the likelihood of catching the COVID-19 virus by touching cardboard or shipping packages is very low. Mark center point with pencil on top and side of rails. This will help seal the exposed wood inside the gunwale. However, Mad River has always used a “capped” deck system on Royalex boats wherein the decks are screwed to the top of the gunwales. Composite hulls require 1 1/4" #8 screws to secure gunwales to hull and 2” #8 screws to secure deck to gunwales. need to be marked on the hull before removal. Trace outside of seat hangers to provide accurate reinstallation. Check to make sure the rails are seated down to marked line and proceed to drill holes at new marks and then insert and tighten screws to secure gunwales. Replacement ash rails are available for all Mad River Canoes. Repeat for deck at opposite end. Slotted inwales are available at additional cost. (If you are short-splicing the installation, let the cut ends of the inwales float inside the canoe. 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. I have an old Mad River Explorer. AA611D Rivet. October 16, 2019, 12:51am #6. Canoes with fine woodwork are a tradition at Mad River Canoe. Mad River Canoe does NOT recommend varnishing the gunwales. If using ¼” hardware insert bolts through rail and reinstall components. This change was made to lighten the canoes and to enable improvements such as double bolting the yokes to prevent rotation. Decks on Royalex canoes have been made of different materials and different woods over the years. 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. At point halfway between the two make mark for center screw on each side. It may be necessary to make adjustments to accommodate existing deck designs. On the average, 80 screws are required to refasten a 16' canoe. Mad River Canoe stocks decks for current canoe models and those that have been discontinued for 3 years or less. Use of spring or bar clamps can be helpful at this point to temporarily. At marks, drill 1/4" holes if using 3/16” hardware and 5/16” holes for ¼” hardware. 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. Attach all hardware to each component to prevent loss. If the gunwales are already grey and peeling, or even cracked, Davidson would call them a” blue run” repair. Depending on model of canoe and date of manufacture, decks may be glued to gunwales or released when screws are removed. The new gunwales also need to treated with a fresh coat of oil. Work towards one end aligning gunwales with top of hull and with each. It is possible to replace a single outwale or inwale or the gunwales along one side if desired. 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. If stained rails are desired, stain rails prior to installation for best results. nothing but the screws where left. It is not an effective protection for gunwales. Here is a pdf file from Mad River Canoe on gunwale replacement that might be of some help: ... My stems are made from inner decks and outer sections that take up the section that the 16ft gunwales come up short. 3 2. Mad River Canoe. Ideally, decks will fit snugly against junction of inwales at stem of canoe. 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. We supply air dried wood because it is easier to bend successfully. Set saw just inside lines and trim off rail to form rounded end with straight side at center of canoe stem. Installing wood gunwales does require a bit more craftsmanship than attaching synthetic gunwales. Slotted rails do cost more than solid rails. The gunwales take a more circuitous route from end to end. need to be marked on the hull before removal. Set inwale in place at end of hull and clamp. 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. Allow 5 to 10 minutes for oil to be absorbed into wood. Remove all screws securing gunwales to canoe. 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. It is best to cut conservatively and hand shape with file or sandpaper to achieve best results. Rails can be ordered from an authorized Mad River dealer. 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 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. Begin the Build According To Your Boat/Ship Type:-If you have a canoe, the gunwale will be located at the top of the side of the boat. Set countersink to length of screw being used (1 1/2" for Royalex hulls). All above materials are available via your local authorized Mad River Canoe Dealer. For 2011, the classic canoe design gets an update and a new hull. All these fittings are hung from existing rails; removal of those rails will result in loss of position of original fittings. Wipe down hull and remove any reference marks remaining on hull. 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. New gunwales are then clamped to the hull and tamped down to ensure they are properly seated. 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. Reference the old screw locations marked on the hull and position new screws to “split” the difference in old locations. Sand top and sides of gunwales and decks with 120 grit sandpaper to smooth finish and remove any pencil marks. If your canoe has walnut or dark stained gunwales and seats you will want to use the dark finish. On composite canoes, the outwale has a “kerf” on the upper surface. Unclamp new inwale and move new inwale below existing inwale and clamp together. 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. 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 Clive. Start your gunwale replacement project by visiting or calling North West Canoe. Allow 5 to 10 minutes for oil to be absorbed into wood. sedges: "I've had lots of wood gunnel canoes come through my shop for gunnel repair or replacement over the years. The T-Formex Remake. If you wish to replace stained rails, it is best to stain them to match existing rails before installing them on the boat. Carefully drill vertical holes through gunwales. It’s usually easiest to start with yoke first and work towards the ends. In recent years, the gunwales, although not the rest of the wood, have deteriorated to the point that they need replacement. Varnish is a surface coat protectant and is adversely affected by the natural flex in canoe gunwales in normal use. Repeat steps #9-17 on opposite rail. Using 11/64" tapered bit and countersink, drill holes for deck screws at marks. The best alternative s to coordinate an order for replacement gunwales with a boat delivery to your dealer. 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. The size change has more impact if you find out that your existing ¼” hardware cannot be re-used and has to be replaced. Collect a handful of sawdust and set aside. It is preferable to drill new holes rather than enlarge existing holes. Use C-clamps to finalize positioning. Repeat for opposite end of canoe. 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