The long and arduous process of making the Black Swan Surf Kayak continues. Once the foam plug is shaped, it needs to be glassed and sanded, primed, then blocked, then primed, then blocked and so on until you get rid of any high or low spots and generate a nice smooth surface. Once we are comfortable with the contours, symmetry etc. of the plug, a flange must be built to be incorporated into the mold for infusion and vacuum bagging. The pictures show the plug during the process of adding the flange. Next step: laying up the mold.
