Uploaded January 2023 | Updated September 2026, 2 weeks ago

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Ever wonder how a canoe is made? This is Step 1. In this video we cover how we take a wooden prototype and build a mould around it in order to reproduce the boat in composite form.

When our designer David Yost fabricates a wooded 'plug', we test it by paddling it in various conditions. We may ask 'DY' to tweak the design here or there, but in many cases he's executed the design perfectly by the time the prototype reaches our crew. Once Bill and the test paddlers are satisfied with the shape, our R&D team designs and builds a production-level mould around the plug itself. Here's how they turn a dream into a reality!

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