INTRODUCTION
Every project has humble beginnings. This one is no different... When I was hired at Legacy, I was asked to review the Ultimate series kayaks to see how we can improve their seating systems. It just so happened that while I was designing a seat for them (see; Slayer Seat Design) at the same time, I had an epiphany. One day I was sitting at home and it hit me, I could cut a part out of our new Slayer model and fit it inside the Ultimate then make it slide back and forth.
The concept was born and the rest is history.
Enjoy!
Enjoy!
This is what started it all...
Lets go to Florida to paddle with the pros.
Lower left; boss man sleeping on the job.
Lower left; boss man sleeping on the job.
Me testing the existing boat in Florida with our pro staff.
Special thanks to Dee Kaminski, Neil Taylor, Ken Taylor & Gator Dave.
Special thanks to Dee Kaminski, Neil Taylor, Ken Taylor & Gator Dave.
Mocking up the system again and again.
SKETCHING OUT THE CONCPETS
To my knowledge, this has not been done before so it took a sketch or two to figure out what to do. Getting the point across isn't always easy without something tangible so prototyping was crucial.
These sketches are just for the cup holder!
This model took me a couple weeks to create.
Draft analysis for deep draw roto parts is critical. The yellow section has less than one degree draft but shrinkage off the outside wall of the tool will negate this small draft.
The parting line was SO critical. It played an important roll in the design of not only this part but the entire boat. Notice the crisp line between the green zone, yellow and red areas, this is a good model!
Draft analysis for deep draw roto parts is critical. The yellow section has less than one degree draft but shrinkage off the outside wall of the tool will negate this small draft.
The parting line was SO critical. It played an important roll in the design of not only this part but the entire boat. Notice the crisp line between the green zone, yellow and red areas, this is a good model!
Counter clockwise from top left:;
1. First REN shape plug. I just thought this was a neat angle...
2. Laying up over the plug to create a composite tool.
3. Prototype mold curing.
4. No PVA and too little wax means we're remaking this mold. Oops!
1. First REN shape plug. I just thought this was a neat angle...
2. Laying up over the plug to create a composite tool.
3. Prototype mold curing.
4. No PVA and too little wax means we're remaking this mold. Oops!
PROTOTYPING
Filling and molding.
Me, testing out the new rotomolded seat base. It works!!!!!!!!!!!!
CONCEPT ASSEMBLY REVIEW
PRODUCTION TOOLING
INITIAL PRODUCTION SHAKEDOWN
SPECIAL THANKS GOES TO:
Shane Benedict, Sam Spear, John Kiffmeyer, Linda McKee, Ken Wright, Brad Stephens, and the whole Legacy Paddlesports team. Also, a special thanks to the Pro Staff for all your input. You're all awesome!
Finally, thanks to my wife and kids for putting up with the long hours; I love you!
Finally, thanks to my wife and kids for putting up with the long hours; I love you!
