Mark point centered 1/2” from point of deck and then ½” from rear end of deck on each side. Apply fresh coat of oil to top and sides of new gunwales. Installing wood gunwales does require a bit more craftsmanship than attaching synthetic gunwales. Brush a coat of Gunwale Guard on the shank of the hardware before inserting hardware into hole. Angle should run so that end against hull will be closest to deck. Seats, yoke, thwart or carry handles are then reinstalled at original locatons and finally a coat of oil is applied for maximum protection. If your canoe has the square gunwales, you will need to plan to replace the decks as well as the gunwales. Holding the rail in place over stem of canoe, trace contour of stem of canoe onto rail so that rail will conform to hull shape. You can use your original hardware or convert your canoe to current standards. Old Town Canoe. 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). For maximum protection of your new gunwales, dip mounting hardware in Gunwale Guard before inserting into gunwales. Starting from one end loosen and remove screws along one side of canoe. The gunnels are installed as bare wood, so the side against the hull never gets treated. In the late 1990’s Mad River switched from ¼” hardware to 3/16”. Prior to ordering gunwales, back out the screws securing the decks to the gunwales to confirm that the decks are not glued in place. In 1985, a new lighter rounded profile was introduced and all replacement gunwales are rounded. 4 piece gunwale set - inners ( 3/4" x 7/8" x length) and outers (5/8" x 7/8" x length). Remove all screws securing gunwales to canoe. These marks will serve as centering points for new rails. The easiest way to tell the size of your hardware is to look at the bolt heads. The rails, seats and thwarts on your Mad River Canoe are native Vermont straight-grained ash, chosen for its resiliency, strength and aesthetic appearance. October 16, 2019, 12:51am #6. They can be used as either outwales or inwales; if you want both, you'll need two pairs. Use C-clamps to finalize positioning. Canoes with fine woodwork are a tradition at Mad River Canoe. Older hardware can be recycled during a re-rail. Clive. Start your gunwale replacement project by visiting or calling North West Canoe. It is not necessary to glue the decks to the inwales. Making sure rails are firmly clamped to each other, pull both rails far enough away from hull to allow both to be cut with a saw. This is the time to make sure that the surface of the rail that will be against the hull will be thoroughly treated with Gunwale Guard. Set saw just inside lines and trim off rail to form rounded end with straight side at center of canoe stem. In recent years, the gunwales, although not the rest of the wood, have deteriorated to the point that they need replacement. Let sit for 5 to 10 minutes and wipe off excess. Treat underside of decks with Gunwale Guard and allow to dry before commencing installation. Prior to 1985, Mad River used square sided gunwales on all canoes. 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. I have an old Mad River Explorer. Cut outwales at a slight angle with point of junction of outwales forming the point of the “V”. The rails are already dipped in a penetrating oil at the factory. ... talk to any canoe dealer that can supply Mad River products. The best alternative s to coordinate an order for replacement gunwales with a boat delivery to your dealer. For best results, however, it is recommended that you replace a complete set of gunwales. Lightly tamp top of bolt to set bolt throat in wood and tighten fully. If you have an older model canoe and the decks are glued to the gunwales, you may want to consider the “short-splicing” process that allows you to utilize those existing decks. So with a saws all I cut away the entire gunwale with an inch of the ribs down to good wood. 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. *C-clamps with round clamp surfaces can tend to walk off the gunwale as you tighten the clamps. It is recommended to drill new holes evenly. This process is described at the end of the following instructions. If there is a slight gap, mix some sawdust from sanding the rails into the glue and proceed to glue as described. It is best to cut conservatively and hand shape with file or sandpaper to achieve best results. 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. If using 3/16” hardware, slide cupped finish washer onto bolt and bolt into hole. Working towards one end, align rails even with top of hull. Make straight line at end of rail by sighting down to opposite end of canoe along keel line. Check to see that new gunwales are on line with line traced on hull at bottom of original gunwales. Below component, place flat washer and lock nut and start nut. Repeat procedure for opposite end. 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. Be cautious not to strip screw heads. **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. There are two alternative processes described in the instructions. The best alternative is to coordinate an order for replacement gunwales with a boat delivery to your dealer. In most cases, the original rail screws are reusable as they are stainless steel and resistant to corrosion. Wood Gunwale Replacement for Royalex Hulls. Even though the outwales are not trimmed at this point, they can be positioned properly to allow installation of screws to secure gunwales. from canoe. 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 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. Remove countersink and drill other holes deeper and insert 2” screws in other locations and tighten. That is the shortest distance between the two points. 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. All above materials are available for order via your local Authorized Mad River Canoe Dealer. need to be marked on the hull before removal. 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. Reposition decks on canoe and drive #8 x 1” Phillips head screws into gunwales below decks to secure decks. Leave other rail. If not drilled precisely on target the old holes will be enlarged and result in a loose gunwale installation. 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. But, some canoes with large upswept en Lightly sand top and sides of gunwales with progression of sandpaper grits. It looks like you may need to call to talk to them about the correct gunwales for your canoe. 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. 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. While we do not sell replacement parts for Mad River Canoes, you can get them from edscanoe.com.You can see what they offer on their Mad River Canoe replacement page. Align the outside rails along the outside edge of the hull. Once these are secured you can release clamps at center.14. Mark center point with pencil on top and side of rails. Hook an “S” hook over hull at each end and put the ends of the outwale in the bottom curve. Start screws in holes and run up tight with Phillips screwdriver or drill fitted with P2 bit. Also trace line of bottom of rail on hull. If they are glued, you will need to order replacement decks as well as new gunwales. For short-splicing installation salvaging existing decks: Make sure that center mark on each inwale is aligned with center mark on hull. 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. The T-Formex Remake. I replaced the gunwales on my old cedar strip canoe some time back. Set inwale in place at end of hull and clamp. 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. 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. Aluminum Gunwale Replacement for Composite Hulls As a lightweight option on our composite hulls, Mad River Canoe offers black powder-coated aluminum gunwales. Slide a piece of wax paper between inwale and hull and then fit the ends together and clamp. We stock full-length wood and aluminum canoe gunwales from Bell, Mad River and Old Town, plus hard to find stainless hardware. To determine new screw locations, run tape measure along inside of rail and mark rail at midpoint between old screw locations marked on hull. Allow 5 to 10 minutes for oil to be absorbed into wood. Repeat for deck at opposite end. Decks will be installed with the more pronounced point at end below the gunwales, not above. Replacement gunwales will need to be treated with Gunwale Guard or equivalent penetrating oil before installation. Original Decks will lift off of hull with the old gunwales. If you do achieve a tight flush fit between the inwales, it is recommended that you drill a 1/4" hole through intersection of inwales where they contact end of hull. This makes this section a bit longer than the corresponding instructions for other types of rails. Repeat for opposite end of canoe. MSRP: $55.99 $49.95 32.0" Stained Cane Seat is ... AA611D Canoe Repair / Gunwale Rivet, Black, Per each. If you are performing a complete re-rail with new decks: The inwale will need to be trimmed to fit inside end of canoe. Hang the top curve over the side of the hull and put the outwale in the bottom curve. Examples of good composite canoes include Mad River (Fiberglass, Aramid, Carbon), NovaCraft (Bluesteel, Aramid, Tough-Stuff, Fiberglass) and Wenonah Canoe (Tuff-weave, Kevlar, Carbon). Mark point on rail where deck ends. 17' Ash Wood, Kerfed Gunwales for Composite Canoes up to 16'5". 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. 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. If fit is good, cover ends of new inwale and ends of existing end pieces with glue. Due to their length, ash rails cannot be sent UPS. It is possible to replace a single outwale or inwale or the gunwales along one side if desired. How to Make Wooden Canoe Gunwales 1. Make sure to coat the ends of the gunwales and if during installation you trim the ends, to coat the newly exposed surfaces. Tighten hardware firmly but do not over torque as it is possible to sheer off stainless steel if over tightened. Seats, yoke, thwart or carry handles are then reinstalled at original locatons and finally a coat of oil is applied for maximum protection. In most cases, the original rail screws are reusable as they are stainless steel and resistant to corrosion. 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. Timeless and Rugged. At that time, Mad River switched to a rounded rail system for a more elegant, finished look and lighter weight. A full set of rails has four pieces: two inside (inwales) and two outside (outwales) parts. Remove decks from gunwales and oil underside of decks as well as the exposed wood from the countersink. 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. spaced between the old, as it is a hit or miss proposition to accurately drill through old holes. Set countersink to length of screw being used (1 1/2" for Royalex hulls). Current Mad River Canoe decks are made of beech. newitem313117035 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. Place point of bit at center of vertical side of rail and drill horizontally. Mad River ash gunwales can be used on canoes of other manufacturers. nothing but the screws where left. 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 Prior to 1985, Mad River Canoes were outfitted with square gunwales. Lightly trace end of deck on top of gunwales. intact. 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. Pencil is better to use to mark gunwales as it will not bleed into the wood like a marker and is easily sanded to be removed. Note which are outwales and which are inwales and mark accordingly with pencil on gunwale (marker will bleed into wood causing discoloration). Replacement rails are available only in the rounded format. $0.65. Step away from canoe and sight along rail to make sure it runs fair. 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 thwarts/yokes, seats, etc. Let dry. Mad River Canoe Cane Seat Stained 32." Over the past four decades, Mad River has manufactured it in 17 different layups. 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. Remove the “S” hooks. Royalex Hull. Repeat process at other end of canoe. Once the gunwales are in place on the hull the new or original decks are fitted into place and secured with 1” screws. The gunwales take a more circuitous route from end to end. Drill ¼” hole vertically through the point of the deck to provide a drain for water trapped when canoe is inverted for storage or transport. You will be doing one side at a time. 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. 3 2. Rails can be ordered from an authorized Mad River dealer. A better job results if all the rails are of the same age and moisture content. This hole will encourage drainage of water when canoe is inverted for storage or transport. Work towards one end aligning gunwales with top of hull and with each. Drill holes at marks with tapered bit and countersink. The kerf is a small extension that will cover the top of the hull laminate. Our customers seldom have a problem installing gunwales because we … Run tape measure around hull under existing rail. Mad River Canoe recommends oiling wooden Gunwales twice a year, more if you store your canoe outside. Canoe parts for repairs, building and more. naturally i really dont want to spend that much on them. On the average, 80 screws are required to refasten a 16' canoe. Canoes with fine woodwork are a tradition at Mad River Canoe. 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 … (Editors note: Drilling holes at the end of crack… Unlike aluminum or plastic materials, white ash will not kink upon impact and cause undue damage to the canoe hull. The ¼” hardware had round carriage bolt heads whereas the 3/16” has a Phillips head. A close fit is desirable but not essential with capped decks as they will cover this junction. All these fittings are hung from existing rails; removal of those rails will result in loss of position of original fittings. Caution should be used not to drill through the inner most part of the gunwale. 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. Used primarily for Gunnel and Top deck installation and repair. New gunwales are then clamped to the hull and tamped down to ensure they are properly seated. The first inwale installed MUST be cut to fit flush against hull contour as well as along a center line INLINE to the "keel" line of the canoe. @mspangler . It may be necessary to make adjustments to accommodate existing deck designs. It is preferable to drill new holes than try to re-use old holes. To re-rail a 14' or shorter canoe you will need 15' gunwales, 15' or 16' canoes will require 17' gunwales, etc. Draw a line bisecting a screw location at a 30-degree angle across the old rail. Maurice, Thanks for reaching out and thank you for working to bring new life to what I am sure is a beautiful canoe! 4 piece gunwale set - 3/4" x 7/8" x length of canoe Clear, straight grain, white ash, air dried. Ideally, decks will fit snugly against junction of inwales at stem of canoe. Remove the screws located approximately 12" from end of decks. 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. Clamp new inwales to old inwales to make sure they stay in place. 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. A Lightweight Canoe for All Occasions Named Named “Best Canoe" – 2019 Paddling Magazine Industry Awards Matching the most versatile hull design on the market with the quality and refinement it deserves, the new Explorer Carbon features resin infusion for a lightweight and durable construction, contoured cherry outfitting, and integrated carbon/aramid gunwales. 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. Using appropriate bit for the hardware being used (1/4” hardware needs 5/16” bit; 3/16” hardware needs ¼” bit). Full length gunwales must be shipped via tractor trailer or picked up at our factory, Call for quote. Return to original end and wipe up any glue that may have run down from gunwale. The inwale will need to be trimmed to fit inside end of canoe. right or left to ensure proper reinstallation. Varnish is a surface coat protectant and is adversely affected by the natural flex in canoe gunwales in normal use. Once you’ve reached end of canoe, return to center point and repeat procedure to opposite end of canoe. New gunwales are then clamped to the hull and tamped down to ensure they are properly seated. This is not a problem. The inwale fits flush against the inside of the hull and its’ top is butted up against the edge of the kerf, concealing the hull. With pencil mark screw locations on inwale at center. Most of the more complex steps occur at the ends of the canoe, from fitting the inwales (inside gunwales) to the stem of the boat and the decks. 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. Define center between older holes and mark gunwale. Due to the length of these gunwales, they must ship via freight carrier on a tractor trailer. 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. Wipe clean and apply Gunwale Guard as described above. Prior to removing original gunwales, the locations of the seats, yoke, thwart, etc. They can be merely ornamental or can be used to tie in gear or be used to set the canoe up as a hunting blind. Mad River debuted the Explorer in 1975 in fiberglass. As you approach end of canoe it will become necessary to drill rails from outside of hull when hull is not wide enough to allow drill to align properly. On the average, 80 screws are required to refasten a 16' canoe. Set rail in place in hull and clamp to make sure both inwales are level. All the wood work can be removed and replaced, leaving your canoe looking great. 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 new gunwales also need to treated with a fresh coat of oil. Mark location of all thwarts/yokes, seats, carry handles on hull of canoe with non-permanent marker. Drill a ¼” hole through junction at ends of inwale to provide drainage for any trapped water when canoe is inverted. Tighten screws to secure gunwales. After the canoe was stripped down to just the hull material, we drilled and countersunk the bottom of each crack so the cracks wouldn’t get any longer, following the procedure used for cracks in metal. My experience with oiled gunnels, especially Mad River, is that they rot from the inside. 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. Clear, straight grain, white ash, air dried We supply air dried wood because it is easier to bend successfully. Sand top and sides of gunwales and decks with 120 grit sandpaper to smooth finish and remove any pencil marks. Align rear marks so that screws will drive into either inwale or outwale rather than hull. The easiest way to tell which size your boat has is the ¼” hardware is crowned with a carriage bolt head whereas the 3/16” is a Phillips head. Slotted rails have cutaways evenly spaced through the central third of the gunwale. (If you are performing complete gunwale replacement: Let the uncut inwale ride up and over the ends of the canoe.) The Malecite, a 16.5-foot … Drill from inside of canoe towards outside, making sure that drill does not go all the way through outside of 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. Mark center point on each side of hull below gunwale. Slotted rails do cost more than solid rails. ** “S” hooks can be made easily from a wire clothes hanger. Move towards each end spacing marks 6” apart along the length of the rail. Also available in cherry. On Royalex hulls, space screw holes at 6" intervals. Angle bit so that the interior end of hole will be just below the bottom edge of the inwales. Wood gunwale replacement might require more craftsmanship than working with synthetic materials but the process need not be intimidating. 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 canoe is about 60 years old and there was dry rot in the gunwales and the edges of the ribs where they come together. On composite canoes, the outwale has a “kerf” on the upper surface. Check other end as well. Older Mad River canoes also used ¼” hardware to suspend seats, attach yokes, etc. The second inwale must be cut to fit against this centerline and hull contour. Reference the old screw locations marked on the hull and position new screws to “split” the difference in old locations. 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. Repeat steps #9-17 on opposite rail. You will be doing one side at a time. New screw locations are marked on the gunwale and countersunk holes drilled at marks. If stained rails are desired, stain rails prior to installation for best results. … Allow 5 to 10 minutes for oil to be absorbed into wood. and transfer from hull to top of gunwales with pencil. Once components are secure, place deck over end of canoe and judge fit. Replacement rails are finished natural. In past, walnut, butternut, cherry, and mahogany have been used. Snug up nut until lock washer is aligned flat. Locate the marks defining seat locations, yoke/thwart, carry handles, etc. Slotted inwales are available at additional cost. Collect a handful of sawdust and set aside. If you are short-splicing the repair, leave these intact and clamp the remaining deck/gunwale ends assembly to the hull. 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. Oak Orchard only recommends canoe models which are proven in real use. Royalex hulls require 1 1/2" #8 screws to secure gunwales to hull and 1” truss head #8 screws to secure deck to gunwales. Position new rails on hull by aligning center marks on new rails with mark on hull. joetaiji. Replace Mad River gunwale, seats, carry yoke? 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. 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