Clearblue NAPALI - Manual (Page 8)

41. The short Kevlar compression struts (parts 17) can now be inserted behind the cockpit and forward of the
foot rests (Fig 18, Fig 19). These struts increase the rigidity of the hull by maintaining skin tension as the hull
flexes. The compression struts snap onto the central deck tubes and the two lower keel tubes. Each pair of struts
are colour coded, the blue ones sit about 30cm behind the cockpit (Fig 18). The red ones sit forward of the
footrest (Fig 19). The struts with two coloured bands are fractionally longer than its same coloured mate and sit
fractionally closer to the cockpit on the deck tube. The position of the compression struts can be varied to
optimize skin tension and the recommended range of positions is marked by the colour coding on the deck
tubes. The struts must be locked in place by webbing straps attached to the deck tube and the longitudinal
tension straps (see Fig 18, 19).
42. The Napali kayak uses Paskal semi dry suit zippers. The zipper teeth are moulded to form a G-lock under
pressure and the zipper may require periodic lubrication. A new zipper may feel more resistant to closure
especially on the curved regions. It helps to feed
the leading edge of the open zipper (with one hand, or finger leading under the slider or just in front of the
slider) into the slider as you close the zipper with the other hand. If the slider binds, do not force it, lubricate the
zipper and use a finger leading before the slider to help
feed the zip into the slider. NOTE: in cold weather the skin will be tighter because of shrinkage of the material.
Also, in cold weather, with a brand new skin, it may be difficult to close the skin. Do not force the zippers.!!! It
is best to perform the initial assemblies in warm weather and allow stretch to occur before assembling in the
cold.
Close the rear zippers as follows. The internal rear zipper MUST be closed to near the frame before proceeding
to close the external rear zipper. However, it may not want to close to the very end of the zipper track. Do not
force the zipper if it really doesn’t want to close. If the skin tension is too tight or loose near the ends of the
kayak, reposition the small mid-frames. If the zippers are hard to close near the rear compression struts,
reposition the struts to reduce the tension. If the zippers are hard to close near the large frames, do not force
them. Instead increase the tension on the rear mid frame skin tensioning straps which will stretch the urethane
around the hull and enable this internal zipper to be closed. Do this a number of times to stretch the skin around
the frame. Now carefully retry to close the inner zipper. Once the internal rear zipper is closed the outer rear
zipper can also be closed.
43. Insert the two fibreglass rods (part 10) through the sleeve in the coaming (Fig 18). Feed them through the
sleeves carefully, guiding the leading edge of the rod through the sleeve. Push the fiberglass rods into the small
black aluminum connector (part 11 small) which is placed in the webbing loops sewn into the skin at the rear of
the cockpit.
44. Close the inner front zipper. If there is too much tension to close this zipper back to near the large frame,
adjust the compression strut position or increase the tension on the forward mid-frame tensioning strap to
stretch the urethane. (the same process as in section 42 applies to the closing of the forward zipper. Do it
carefully. Do not close the external forward zipper yet.
45. Attach the coaming connector (part 11 large) onto the other end of the fiber glass rods at the front of the
cockpit (Fig 20). The ends of this alloy tube will extend slightly into the coaming side pockets.