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Re: Falco Folding Kayak

Posted: Tue Jan 14, 2014 6:51 am
by dschin
@chris:
do you glue the panels and the skin together???

Re: Falco Folding Kayak

Posted: Thu Jan 16, 2014 1:08 pm
by gmchris
dschin wrote:@chris:
do you glue the panels and the skin together???
Hi dschin, not sure if you were asking me, but here's how I did mine.

Mine in it's finished state is similar to Tom's Falco, but it doesn't fold (I must admit I'm not as clever as Tom, I used his Falco for inspiration and adapted the design to suit my lack of skills lol). The skin of my boat is laid out, then the front and rear halfs of the frame are inserted through the cockpit and fixed together - like a traditional folder assembly.

To make a 12ft kayak i used 4 panels each side as I wanted the packed length to be 3ft or so. I didn't want to use any wood as I am not confident of sealing it, so I used ACM sheet ( 3mm aluminium-faced plastc sheet) 3ft 3inchx 11inch each. I overlapped each panel by 3inch and bolted together with 2 6mm smooth-headed bolts (called 'roofers' in the uk) at each join. I bolted all apnels together to give 2 full length sides, then taped them together at bow and stern. Then open them in the centre to be 24inch apart, and measure the widths at the cross section positions, and make 4 12mm plywood crosssections. I then assembled the frame ( that is sides and crossectons all in place and temporary taped in position) and skinlike you would withany other frame. To dis-assemble, start by removing the bolts in the cockpit to seperate front of frame from the back half, and pull out of the cockpit peice by peice.

The finished boat is a bit 'tippy' as I am a novice paddler, but a floor panel in the cockpit may help. I posted another thread on this somewhere ( 'advice on keel position' think it was called)

Please bear in mind this is Tom's baby really, my de-engineered interpretaion of the falco is just a stop-gap to satisfy my curiosity as I have always wanted a kayak and couldn't wait. :)

Re: Falco Folding Kayak

Posted: Sat Jan 18, 2014 9:30 am
by dschin
hi chris

all ok, when I saw the pic I assumed that.

at the moment I am testing following idea

panel > insert > panel

the panels are glued to the skin
the removable insert is connected with the panel with puzzle cuts. so I do not have gaps

panel, insert, panel are additional fixed with yost's fixing

br from vienna

hannes

Re: Falco Folding Kayak

Posted: Wed Jan 22, 2014 5:46 pm
by gmchris
dschin wrote:hi chris

all ok, when I saw the pic I assumed that.

at the moment I am testing following idea

panel > insert > panel

the panels are glued to the skin
the removable insert is connected with the panel with puzzle cuts. so I do not have gaps

panel, insert, panel are additional fixed with yost's fixing

br from vienna

hannes
Sounds good!
Not sure what you mean by puzzle cuts- like a jigsaw?
Since completing mine I have reworked the panels with 'fingers' that interlock at the ends so there are no bolts just slots together, maybe a similar idea?

Its good to experiment and evolve (even the mistakes help us learn lol)

Re: Falco Folding Kayak

Posted: Thu Jan 23, 2014 10:57 am
by Lodeon
don't you fear the puzzle cut could snap out the position due to the water stressing the frame?
I suppose butt jointing the panels could be easier and better. IMHO

Re: Falco Folding Kayak

Posted: Fri Jan 24, 2014 2:50 pm
by dschin
a quick scribble
Image

black: panel
red: insert
blue: lock like yost

so the insert will be fixed to the panels in lenght-direction and with the yost-lock to the panels

Re: Falco Folding Kayak

Posted: Fri Jan 24, 2014 7:51 pm
by gmchris
Lodeon wrote:don't you fear the puzzle cut could snap out the position due to the water stressing the frame?
I suppose butt jointing the panels could be easier and better. IMHO
My side panel joints have landed where the crossections are, so they can't flex inwards, the crosssections are in the way. The centre join has a 'lower half' crossection -sits just below your knees.


dschin wrote:a quick scribble
Image

black: panel
red: insert
blue: lock like yost

so the insert will be fixed to the panels in lenght-direction and with the yost-lock to the panels
Yeah that would work, looks more intricate than mine, but stronger too.

Re: Falco Folding Kayak

Posted: Mon Jul 28, 2014 4:14 pm
by trigger
No updates?

V/R
Adam

Re: Falco Folding Kayak

Posted: Wed Oct 08, 2014 2:28 pm
by oninesm
AndrewB wrote:Does anyone have a video on how the Falco unfolds? Can't quite envision it, and beyond that, I think I can begin on making a set for my wife and me.
You fold the cross sections flat against one of the sides, bring the two sides together, then accordian fold the entire boat at the 4" gaps between side panels, like so: ____ --> /\/\/ --> ||||


I hope that verbal description helps, because the ASCII sure doesn't make it any clearer.

Re: Falco Folding Kayak

Posted: Wed Nov 12, 2014 4:42 pm
by gmchris
Guys I think you are over thinking this.

All you need to do is look at toms photos of the cross sections and scale them up. To decide the cross section sizes, I made 2 12ft side panels (4 3ft lengths each), by 11inch high, taped them together at bow and stern, then pulled them apart in the centre until they formed a kayak shape 24inch wide. I then measured the width between the panels at each cross section position and made them to suit.

If you wanna practice with the design, try a scale model first, 12inch long. cut some cereal box to make two 12inch panels and sellotape them together, then pull them apart to see how they flex. Spread the top edges more and you will see the bow and stern curl up nicely.

A friend asked me to make one for his wife who was fed up with her inflatable canoe because it didn't track at all. But he said mine was very low in the water and a bit tippy. So when I made theirs i simply made the side panels an inch taller, and made the cross sections 1.5 inches wider to give a more stable kayak. I suppose you could even upscale it to a tandem if you keep adding length and width.

Seriously, some time spent sat down with scissors, card, tape and a ruler will give you a frame model and confidence to start building.

Re: Falco Folding Kayak

Posted: Sun Jan 03, 2016 1:29 pm
by dschin
where may I find the pics of Falco???

Re: Falco Folding Kayak

Posted: Fri Jan 15, 2016 5:40 pm
by gmchris
Tom didn't post falco pics on his website, but you may find them on various forums.

If you Google "falco folding kayak" and select images the first half a dozen are toms falco (it's the one made from Red pvc with plywood cross sections)

Re: Falco Folding Kayak

Posted: Sun Jan 17, 2016 4:06 am
by dschin
thanks

are there anywhere the design with measurements??
I consider to use dropstitch-fabrics instead of plywood

Re: Falco Folding Kayak

Posted: Wed Jan 20, 2016 4:08 pm
by gmchris
Don't think there are any with measuments. I made mine by making 12ft ply sections, taping them at bow and stern, then pulling them apart in the middle till they were 24inch apart. Then I made the 4 crossections whatever they needed to be to fit. Taped it temporarily together and skinned it.

Re: Falco Folding Kayak

Posted: Thu Jan 21, 2016 6:13 am
by dschin
Hi Chris,

i'm asking because on page 1 of this thread Tom is mentioning
http://www.yostwerks.com/Falco16All.jpg - Falco 16 drawing

this jpg and all the other ones from his homepage are not availible - neither on yostwerks.org nor on the wavybackmachine.

brgds hannes