Instructions – Ultralight Kits

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

Seat 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

Step 4 – Join Tube 2R to 3R

Step 5 – Add Tube 1R

Optional – Installing an Airtight Zipper

Step 6 – Add Tube 4R

Step 7 – Add the Left Side Tubes

Step 8 – Seam Sealing

Step 9 – Front Center Seam

Step 10 – Install a Boston Valve

Step 11 – Rear Center Seam

Step 12 – Inflate & Test for Leaks

Step 13 – Make a Seat (Pre-2022 kits only)

Step 14 – Tie-Downs & Attachment Points (optional)

Questions? Leave a comment below!