Kit Checklist
Note: Do not use a knife to open your kit, as you may damage the fabric.
Before beginning construction, identify the parts of your kit and place the pieces someplace where they won’t get lost. Please unpack your kit carefully, as small pieces (like valves) can be overlooked when wrapped in fabric and/or packing materials. Each kit includes:
- Eight fabric tube pieces, numbered 1-4, L & R (Left and Right), in the color of your choice, with the forward direction indicated by an arrow; eight reinforcing strips (strips of fabric of various lengths, 5 cm or 2″ wide with pointed ends); a ring of fabric for mounting the inflation valve (inner diameter 40 mm, outer diameter about 120 mm) – all of the above are typically scored into one large sheet of fabric
- Inflation bag fabric – same fabric as the tube pieces, a rectangle approximately 1 x 1.5 m (3′ x 4.5′) – typically attached to the tube fabric described above
- One heat sealable Boston valve (black, three parts)
- Two top-up valves (black valve stems and black+white valve ends)
- One black fabric floor piece (with alignment dots and forward arrow indicated in silver pen)
- Seam strips, black, each approximately 30 mm (1.25″) wide and 2 m (6′) long
- Inflation bag adapter tube (black silicone tube, approximately 5 cm or 2″ long)
- Small piece of heavier black fabric, at least 10 cm (4″) square (for mounting inflation bag adapter tube and for making reinforced attachment points)
- Scrap fabric surrounding the scored packraft pieces (for heat sealing practice, making small accessories, repairs, etc.)
- A letter including your password to the instruction pages linked below (do not discard!)
- Non-stick baking paper for mess-free heat sealing
- Optional: airtight zipper + zipper lubrication + rectangle of heavier black fabric large enough to mount zipper
Before You Begin
Before starting on your packraft, you may need to modify your iron, and if this is your first heat sealing project then you will definitely want to ensure you’re using the proper heat sealing technique by practising with some scraps of fabric to dial in the correct temperature on your iron.
Please familiarize yourself with this page: Practice Proper Heat Sealing Technique (important!)
You may also want to build confidence by constructing your inflation bag first and then make your backrest and seat before constructing the packraft itself.
Depending on the iron you’ve purchased, you may choose to modify your heat sealing iron to make it easier to use.
Ultralight DIY Packraft Kit Instructions
Please familiarize yourself with the instructions before you begin – you’ll be much less likely to make a mistake if you understand what you’re doing and why.
Instead of trying to memorize the steps, watch a video once all the way through and then watch it again as you work, pausing frequently so you can catch up.
Note: Be sure to review the pictures and written notes on the instructions pages – not just the videos. I can’t re-edit a video each time someone asks a question, so the text is where I add clarification and emphasis in response to feedback from builders. If you only watch the videos, you may make mistakes that are warned about in the text.
Note: Due to an issue with a copycat website, access to the following pages is limited to those who have purchased a kit. The techniques are similar to those used in the V2 DIY Packraft instructions, which are not password protected, but the packraft design and assembly methods have been improved. Your password for these pages is included in the letter packed with your kit (it is not the same as your Forum password). Please do not reproduce the instructions or share your password.
Note: If you do not have a phone/tablet/computer where you will be constructing your packraft, you might choose to print the instructions – if you do so, I recommend printing them only as you need them to ensure they are up-to-date, because I frequently update instruction pages in response to questions from customers.
Tip: When watching the videos in the links below, you can press the arrow keys on your keyboard to scrub back and forth. Also, if you click on the gear icon in the video player you can adjust the playback speed.
Inflation Bag Assembly Instructions
Backrest Assembly Instructions
Ultralight Packraft Assembly Instructions:
Step 1 – Separate & Identify Fabric Pieces
Step 2 – Seal Tube 3R to Floor
Step 3 – Add Adjacent Tube Piece 2R
Optional – Installing an Airtight Zipper
Step 7 – Add the Left Side Tubes
Step 10 – Install a Boston Valve
Step 10.5 – Add a Seat Attachment Point
Step 12 – Inflate & Test for Leaks
Step 13 – Apply Sealant to Outside of Seams
Step 14 – Tie-Downs & Attachment Points (optional)
Questions? Leave a comment below!
6 Comments
JYP · April 20, 2023 at 9:34 am
Hi,
This is awesome. Seat, backrest and inflation bags are done and seem bombproof so far.
Is there anywhere on this site that shows what damaged TPU looks like on the UL fabric? I think I may be going overboard on the patching. The TPU always looks a little gray on the black fabric around the edges of where I sealed. So far I’ve been patching it all but I wonder if that’s really necessary. Do you have anywhere on this site pictures of TPU damage when the airtightness is compromised vs heat scuffing that’s fine?
Thanks for this awesome project.
JYP
Matt (Admin) · April 20, 2023 at 9:54 am
Hey, that’s great! The bottom of the floor fabric will look a little different after heat sealing tubes to the other side, being slightly less shiny/lighter (you can kind of see it in the last picture on the Step 2 page) – I think maybe that’s what you’re referring to. I don’t think I have a picture that shows too much damage, but if you email me a picture of what you’re seeing I’ll take a look. Note that if it is the bottom of the floor fabric you’re referring to, it wouldn’t necessarily need any patching even if it is slightly damaged because there’s another airtight layer on the other side of the fabric (where the tube fabric is attached), so it can’t leak there.
Dennis Two questions · January 22, 2021 at 9:01 pm
Two questions.
1. The inflation bag is made from the separate yellow fabric that is the same as the tubes correct?
2. There is a square of yellow fabric that is very different than the yellow or black fabric. What is it for? It’s about 12″x31″and is thicker and denser and stiffer than the other fabric. Note I bought two UL at the same time so it could be double the size. But I don’t know what is for.
Thanx
Matt (Admin) · January 25, 2021 at 8:49 am
Hi Dennis,
1. That’s correct (in later kits, anyway). You might choose to use that fabric for something else and make an inflation bag out of DCF or a plastic bag if you’re trying to save weight.
2. That’s for mounting the zipper. I normally supply black fabric for that purpose, but I do not have any black at this time so I used yellow to match the tubes. Cheers
Birgit Kühn · April 28, 2019 at 1:24 pm
Hej Matt!
I wonder if i was heating the fabric to mutch whilst practising today. I could see the ripstop pattern on the outside of the floor fabric.
Is that normal för the ultralight kit and the use of a silikon roller?
Yours sincerely, Birgit
Matt (Admin) · April 29, 2019 at 7:24 am
Hi Birgit, thanks for checking. It’s difficult to say for sure without seeing a picture, so I will send you an email. Cheers!