2-Person Packraft Assembly

Note: These instructions are for the 2019 (and later) version of the 2-Person DIY Packraft kit; for the older “Voyageur” two-person packraft, please refer to the V3 assembly instructions.

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:

• A letter including your password to the instruction pages and videos. Do not discard!
• Pre-scored fabric in the color of your choice for making the packraft’s tubes, numbered 1-4, L & R (left and right), with the forward direction indicated by an arrow
• Pre-scored black fabric for making two inflatable seats and ten attachment points
• Pre-scored heavy black fabric with alignment dots and a forward arrow indicated in silver pen for making the packraft’s floor. This piece also contains ten pre-scored attachment point reinforcement parts.
• Three heat sealable Boston valves (black, three parts each)
• One top-up valve (black valve stem and black+white twist valve)
• Three pre-scored seam strips (long black fabric, approximately 4 m or 13′ long)
• Inflation bag fabric (lightweight red or black ripstop fabric, approximately 1 x 1.5 m, or 3′ x 5′)
• Inflation bag adapter tube (black silicone tube, approximately 5 cm or 2″ long)
• Scrap fabric (this is all of the fabric surrounding the scored shapes). Use it for heat sealing practice, making reinforcing strips, repairs, etc.
• Non-stick baking paper for mess-free heat sealing
• Optional: airtight zipper (tucked into the folded floor fabric) + lubrication tube

Before You Begin

Important: Before starting on your packraft, take some time to ensure you’re using the proper heat sealing technique by practicing with some scraps of fabric to dial in the correct temperature on your iron. This page will help with that: Practice Proper Heat Sealing Technique

The above video shows me demonstrating the DIY Packraft heat sealing technique. It’s a bit long and rambling compared to my scripted videos, but it’s useful to see the iron working in real time and it shows how strong the heat welds are when done correctly. If you follow along you’ll be well on your way to creating good, strong, seams.

Depending on which iron you’ve purchased, you may choose to modify your heat sealing iron to make it easier to use.

2-Person 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.

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. 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. 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.

Note: If you do not have a smartphone, tablet or 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 readers.

Before starting the packraft itself, you may want to build confidence by completing your inflation bag and seats first:

• Inflation Bag Assembly
• Canoe-Style Seat Assembly

Here are the instructions for assembling the packraft (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 change the playback speed.):

Inflation Bag Assembly

Seats (canoe-style) Assembly

Step 1 – Separate & Identify Fabric Pieces

Step 2 – Seal Tubes 3R & 3L to Floor

Step 3 – Add Tube Pieces 2R & 2L

• Notes About Seam Sealing

Step 4 – Tube Pieces 1R & 1L

• Optional – Installing an Airtight Zipper

Step 5 – Tube 4R & 4L

Step 6 – Front Center Seam

Step 7 – Install Boston Valve

Step 8 – Rear Center Seam

Step 9 – Inflate & Test for Leaks

Step 10 – Tie-Downs & Attachment Points

Questions? Leave a comment below!