Clearblue NAPALI User Manual
Page 5
• By pulling outwards and/or upwards with the hand closest to the bow, open the expansion joints as wide
as possible. This will usually involve part of the rod bending outside the skin, so you need to ensure that
the rod does not become caught in the skin. See Figure 8: the outermost two tubes in this image have
been forced out wide and the expansion junction has opened up. Make sure that the expansion join is
opening up and not one of the other tube junctions. If the rods pop out of the front frame this does not
matter at this stage. Avoid rotating the tubes as this can result in separation of the tube from the end
frames.
• Although you may find that you can do this first time with no problems, inserting the expansion clips
(part 14) is the assembly stage that most people find is the hardest part of assembling a Napali kayak.
Please remember the following points:
o
This can be done by a wide range of people. Brute force is not required and if you find yourself
huffing and puffing you’re going about it the wrong way.
o
If you are having difficulty, check that the rods are able to bend freely outside the skin. Check
also that the foam end-units are fully inserted into the bow and stern of the skin, and that the end
frames are properly engaged with them.
o
The carbon Kevlar rods will not split or break – they need to be bent some distance outside the
skin.
o
You do not have to open the expansion joint fully the first time you pull on the rod. Repeat the
process a few times. Although they will tend to contract back on release, each time you do this
the structure is elongating and the end-units are moving further apart. Try not to rotate the rods
as you do this as you may inadvertently unlock them from the end frame.
o
You will find that for some of the rods it is easier for you to lift the rod vertically, while for other
rods you may prefer to pull the rod horizontally.
• Take the expansion clip that is at the appropriate end of the cord and clip the trailing end of the clip
(away from the eyelet) onto the stern end of the expansion junction. Make sure that the correct
expansion clip is attached to the correct tube so that the cord passes naturally from eyelet to eyelet
without interference (Fig 11).
• Snap the eyelet end of the expansion clip into position. It is very important to check that the expansion
clip is fully snapped in place throughout its length.
17. Using the process in 16 above, insert the expansion clip into the second red coded rod.
18. Using the process in 16 above, insert the expansion clip into the yellow and blue rods. Do the yellow, then
the blue on one side. Repeat the process on the other side.
The yellow coded tube can be the most difficult to fully expand as this tube is the longest. If difficulty is
encountered with fully expanding this tube (or others), attach the clips to the other tubes first. The gradual
elongation of the structure will make attachment of these final clips easier.
19. Check that the seat is positioned well forward of its eventual position. Expand one of the green rods by
lifting it vertically, and attach the expansion clip. Repeat for the second green rod.
20. Make sure that all the clips are in position and are fully snapped in place over the full length of each clip.