DIY Packraft Kit: Ultralight

• The Ultralight DIY Packraft is now available in red, yellow, and blue.
• Seam strips and seat are now black (not the same color as the tubes, as is shown in some pictures).
• An ultralight seat and backrest are now included in the kit.

The Ultralight DIY Packraft is specifically designed for faster travel, both on and off the water. Made of very lightweight ripstop fabrics, it requires more careful use than a regular DIY Packraft and is not suitable for difficult whitewater paddling, but by sacrificing some strength, the weight and packed size are cut in half – it’s so small and light that you won’t think twice about bringing your packraft on any hike!

Other “ultralight” packrafts on the market achieve their low weight by reducing their size and rounding the ends so they are slow on the water and are easily swamped by waves. The Ultralight DIY Packraft is a full-size packraft made with ultralight fabrics, so it’s faster and comfortable enough for all-day paddling with a full load of gear in a wider range of conditions.

In spite of its light weight, the Ultralight is still durable enough for many people’s needs. I occasionally carry my wife with me in an Ultralight or paddle in Class 1+ rivers, and one customer who built an Ultralight emailed to say, “By the way last weekend I took it through a very dicey little river between two lakes where it rubbed against a bunch of sticks on both sides from a destroyed beaver dam and it held up great. Impressive.” He also sent pictures of himself paddling through ice in the arctic. I’m not claiming it’s indestructible – it’s just a more capable boat than many people assume.

The Ultralight DIY Packraft is also the quickest and easiest DIY Packraft kit to assemble – instructions are posted here.

Specifications:

• Internal length: 130 cm (51”) – one size fits most (size information here)
  
• Weights (approximate):
  • packraft (can be used without the seat and backrest): 815 grams (1.7 lbs)
    
  • seat: 100 g (3 oz)
    
  • backrest (also makes a great camping pillow): 50 g (1.75 oz)
    
  • total: 965 g (2.1 lbs)
• Packed size: 14x14x35 cm (5.5×5.5×14”)
• Capacity: 135 kg (300 lbs)*
• Tube fabric: 115 GSM ripstop (red, yellow, or blue)
  
• Floor fabric: 190 GSM ripstop (black)
  
• Build time: 20-30 hours
  

*Learn about packraft capacity ratings here.

Kit includes:

• Pre-scored and labeled 115 GSM (3.4 oz) and 190 GSM (5.6 oz) heat sealable ripstop fabrics for making the packraft, seat, and backrest.
  
• Heat sealable Boston valve for inflating and deflating the packraft
• Two top-up valves for use in a seat and backrest
  
• Inflation bag kit for quickly inflating your packraft (can be modified for use as a drybag as well)
  
• Extra fabric for heat sealing practice and for making small accessories and repairs
• Non-stick paper for clean heat sealing
• Access to detailed text, video, and picture instructions, plus online support
• (Paddle, PFD, etc. not included)

Tools required for assembly (not included):

• Heat sealing iron
• At least one tube of Seam Grip+WP seam sealer (I recommend purchasing this locally). Aquaseal and Aquasure are suitable alternative sealants (all are made by Gear Aid).
  
• Masking tape
• Permanent marker (silver works best on dark fabrics)
• Ruler and/or tape measure
• Sharp scissors
• A few wooden blocks of various sizes
  
• A heat resistant bowl or heat sealing forms to drape the fabric over
• An internet connection to view the instructional videos

Additional recommended tools and accessories:

• Leather gloves to prevent burns when heat sealing
• Rubber gloves for use when applying seam sealer
• Talcum powder (baby powder or foot powder) for covering seam sealer while it cures

Airtight zipper option: An airtight zipper allows you to store gear inside your packraft’s tubes and to easily access the inside of the packraft for repairs. Both zipper options are high quality airtight zippers made in Germany, and both are rated to 700 hPa or 10 PSI air pressure (much more than the pressure in a packraft). The MasterSeal is lighter and easier to install, operate, and clean, and it has a single seal. The SuperSeal is heavier and more difficult to install, operate, and clean, but has multiple seals. A MasterSeal zipper will add approximately 65 grams (2.5 oz) to your packraft’s weight. A SuperSeal zipper will add approximately 125 grams (4 oz) to your packraft’s weight.

Note: The weight and dimensions in the “Additional Information” tab are for shipping the kit with all of the additional scrap fabric and packaging. They do not represent the final weight and packed dimensions of a completed packraft.