How Bellyaks are Made

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We’d like to think a stork magically appears and drops off new bellyaks to people all over the world. Or that they sustainably grow out of bellyak seeds.

Unfortunately, neither of these options are feasible for mass production. Instead, the bellyaks are rotationally molded at BIG Adventures in Fletcher NC. Rotomolding is as much of an art as it is a science. Two people can make the same cake recipe, but Grandma’s will come out much better, because of EXPERIENCE. This is why we partner with BIG Adventures: they have years of experience in molding plastic kayaks. This is the team that makes Liquid Logic Kayaks and Native Watercraft. In fact, we use the exact same polyethylene powder formulation used in all Liquid Logic whitewater boats. This means bellyaks are incredibly durable and will basically last you forever. And ever.

Making a bellyak

The molds are cast aluminum, only made after many iterations of the product have been done. To read more about the development process ‘click here’.

Step 1: Dialing in the Recipe

Before a model goes into production, the mold is attached to the arm of the oven and goes through several cycles to measure plastic thickness. They also dial in the ‘shot weight’ – or appropriate amount of powder – to find the optimum balance between thickness and keeping it  as light as possible. From here, we develop a specific recipe for each bellyak insuring consistency and quality molding.

Measuring the powder in the bellyak mold

Step 2: Preparation

Our graphics are applied in mold, becoming part of the boat as they ‘cook’ into the plastic.

Applying the graphics to the bellyak mold

Brass inserts are applied for handle attachments, and then pre-measured polyethylene powder is placed in the mold. At this point the two halves of the molds are clamped shut.

Step 3: Cooking

The mold moves into the cooking chamber to cook at 525 f for 14 minutes. This is where the magic happens. As the mold heats it is rotated on two axes (rotation dialed in specifically for each model). The powder liquifies and coats the inside of the mold as it rotates. After this it is moved into a cooling chamber where the mold continues to spin as the temperature is brought down in a controlled environment.

Bellyak heading into the cooling chamber

Step 4: Cooling and assembly

While the boat is still warm, but not hot, it is removed from the mold and placed in a cooling fixture. At this point the excess plastic is trimmed and the whole bellyak is flamed with a heat gun to give it a super glossy finish.

Inserting the snack hatch to the bellyak

Handles, hatch, skeg, pad are all installed, and the bellyak goes through a final inspection process before being placed in the rack.

The bellyaks are stored in a rack

Step 5: Shipping

Once an order is placed, the boat is bagged in a heavy felt bag and shipped anywhere in the world! It is delivered to you for prone paddling awesomeness wherever you are!

Don’t like to read? Us neither. Just watch this video instead!

How Bellyaks are Made

Swim training for bellyak

Training in the Off Season for Prone Whitewater Greatness

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It’s true that one of the most popular off season workouts involves watching YouTube and drinking beer.  While this is one of the top training methods for marginal athletic performance, this approach results in startling feelings of being out of shape after a long cold winter. We suggest another route: intentional training for the activity at hand.

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French Broad Section 9

Five Hidden Gems to Paddle in Western North Carolina

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There are no shortage of beautiful waterways to bellyak on than in our home region of Western North Carolina. Not only do we have killer BBQ and more craft breweries than we can count on our fingers and toes, but we also have more than 400,000 miles of waterways in the whole state. You better keep them a secret, but here are our top 5 WNC rivers to paddle:

1) Section 8 of the French Broad

The French Broad River is the second oldest river in the world, which makes it older than my great, great, great granddad. And he’s old. So old in fact, that it has developed a certain smell only found in this particular waterway. Although the whole river is great to paddle, Section 8 is one of our favorites.

This is a 5 mile (ish) section downstream of Marshall NC, about 30 minutes north of Asheville NC. Section 8 begins below Redmond Dam, and takes out at Barnard (the put in for the most famous section: Section 9). Section 8 is rarely traveled, but is the perfect section for new paddlers, or those looking for a family friendly float. There are no real ‘rapids’ on this section, but what makes it fun is that there is consistent gradient from put in to take out, making for a nice ‘moving sidewalk’ of current. There are also many eagles and otters that live along this mostly unpopulated stretch of river. If you’re also on the hunt for somewhere to stay, one of the French Broad River Paddle Trail campsites is on this section. 

 

2) Section 9 of the French Broad

Are you seeing a pattern here? This section has been written about before, and is the location for the evolution and development of Bellyak more than any other stretch of river. This is a great section for beginning whitewater training, with an instructor. In the four mile stretch of river between Barnard and Stackhouse, there are multiple Class 2 and 3 rapids that offer many different ways to go down, from easy straight down the middle to maze like runs that require precise navigation. At higher levels this section can be quite pushy due to the amount of volume coming down the river.

For Section 9 rapid by rapid, check out our Where to Bellyak: French Broad Section 9 post here.

3) Lower Nolichucky

This section of river, beginning at USA Raft in Erwin TN and ending at Jackson Love Bridge, is a perfect section for those looking to taste a little whitewater action in a perfectly clean and pristine river. The Lower Nolichucky is approximately one hour north of Asheville, and flows year round. Contact the folks at USA Raft to book your trip. They have expert guides, hot showers, and beautiful accommodations right along the river.

 

via GIPHY

4) Nolichucky Gorge

On the books to be named a Wild and Scenic River, the Nolichucky Gorge flows through the deepest gorge in the Southeast. Over 8 miles of amazing whitewater that will delight and test the most avid of paddlers. Rapids such as Quarter Mile, surf spots like Jaws, and miles of beautiful scenery in a pristine gorge make for an amazing day on the water. For those inexperienced, having the experts at USA Raft guide you down is the way to go.

5) Big Laurel

40 minutes north of Asheville is the best section of whitewater Bellyaking known to man. The Big Laurel River. Flowing out of the shadows of Mount Mitchell, the Big Laurel is a tight, low volume creek popular with fisherman that flows into the French Broad River below Stackhouse. The Big Laurel has a trail running along the side which allows for easy scouting and portaging if necessary. Rapids such as Triple Drop, Suddy Hole, and the Narrows provide exciting, technical rapids in a  beautiful setting. Check with the folks at Laurel River Store for good levels. Levels from 3” to one foot are ideal. Over a foot and the spice level goes up exponentially. Great surfing right at the put in at Cabin Wave.

Prone River Surfing

Prone River Surfing

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By Adam Masters, bellyak Founder

There is no better feeling than having your face inches from the water while watching the river rush by. Going fast while sitting still. Prone river surfing causes time to stop, and everyone remembers their first time better than prom night. For most, it’s the only anniversary that matters. Most impressions of surfing conjure up Gidget standing effortlessly sliding down a perfect TV wave with nothing but palm trees and coconuts for miles. Those of us lucky enough to not go to bed every night stuck to sandy sheets have to look for our own endless wave, the waves created by the timeless forces of rocks, water, and gravity.

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Outdoor Gear Builders Holiday Gift Guide

2018 Outdoor Gear Builders Holiday Gift Guide

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Whether you’re on the look out for the perfect holiday gift for the outdoors adventurer in your life, or you’re shopping to treat yourself this year, you don’t have to look much further than right here in Western Carolina. From climbing equipment, to snuggly sustainable apparel, to new boats, welcome to your home-grown holiday gift guide by the Outdoor Gear Builders!

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Why We’re 100% Made in USA

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Some of the world’s most ingenious creations have been thought up and made right here in the USA, such as  Harley Davidson Bikes, cheese burgers, and 3D printing.  Did you know the bellyak joins this prestigious list too? In fact, we are 100% made in the USA. The handles, hatch, and pad all come from North Carolina, and graphics from Arizona. They are expertly molded at BIG Adventures in Fletcher, NC, who are also the molders behind Liquid Logic and Native Watercraft. Sure, we could have our boats made in China for a lot cheaper thus sell our boats for less, but there are loads of reasons why we don’t want to do that – and neither do you! Here’s our top 3:

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Bellyaking on the French Broad

Where to Bellyak: French Broad Section 9

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Standing in the shadow of so much gnar, Section 9 of the French Broad is often overlooked as a beginners-only run. Only 45 minutes from Asheville and with a quick shuttle, Section 9 is good at almost all levels. It is a popular run for SUP, bellyak, and all other manner of river craft, due to the year round flows, beautiful scenery, and good play. The multitude of read and run rapids don’t hurt either.

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What Heretical Ideas Are You Willing to Embrace?

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re-posted with permission from the author

I love motorcycles. I’ve spoken at the Motorcycle Industry Council, I’ve met with the majority of the original equipment manufacturers (OEMs), and have visited with over 100 dealers in recent years. But the motorcycle industry is one of many that’s battling a stagnant or shrinking market, and the only solution is for it to quit one or more commonly-accepted practices.

Industry experts and veterans hate to hear advice like this. Try telling a scratch golfer that you think one way to make that sport grow again is to double the size of golf holes. “Outrageous!” s/he is likely to exclaim, without suggesting an alternative solution to shrinking year after year after year.

The problem with these industries is that existing players like things the way they are. Sure, they’d prefer more growth, but not at the price of changing long standing practices.

For example, the only thing keeping the ski industry afloat is the rise of snowboarding. This was not the result of innovative practices on the part of ski industry OEMs, but rather the disruptive influence of upstarts like Burton, which popularized snowboards.

To put it another way, the practice Burton “quit” was to stop making sliding devices in two pieces. Creating a single board—which sounds like a simple innovation—had tremendous ripple effects. It provided more of a surfing experience, completely changed the athlete’s stance, which changed their clothing needs, and also shifted the age and mindset of new participants. Plus, to be brutally honest, it probably kept numerous resorts from dying.

My problem with such industries is that they’d rather iterate than innovate. Instead of disrupting their own traditions, they tinker around with modest, almost negligible changes. Engines get a little more powerful or efficient. Tires get a little larger. Nothing much changes from one year to the next, and such industries continue to stagnate.

For example, I have friends and clients who have stopped attending certain trade shows because the amount of innovation from one year to the next is virtually zero. In some industries, like technology, you can’t afford to take your eye off the ball for even three weeks; in stagnant industries, you can coast for a year or two, and it doesn’t really matter.

If this sounds familiar, forget about all that nonsense at the edges and ask yourself two questions:

  1. What long standing practices are we willing to quit?
  2. What heretical ideas are we willing to embrace?

Without bold answers to these questions, your future will look very much like your recent past. For example, in 2007 the motorcycle industry sold about one million new bikes. This past year, I think the number was somewhere south of 400,000. Do the math… that’s simply not a sustainable trend.

David Nour helps leaders connect with their teams by using the right strategy, pictures, and words. His tenth book is Co-Create: How Your Business Will Profit from Innovative and Strategic Collaboration. He is also a popular speaker.

Why I love the Play 35

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I just love it, so no more stupid questions

 

The reason I love the Play 35 is the same reason Bill Wunderlich, 2 time Tennessee State heavy weight wrestling champion loves the Play 45:  it just fits. When I first cruised on a Bellyak I made it down the Class 4 waters we were paddling with a huge smile on my face. I’m sure that was the only pretty thing that day because I had only a taste of what was possible. Now, 2 years later, my bellyak and I  have been getting down right nasty. While the barrier to entry is low on a bellyak, the level that you can take it athletically seems to be limitless at this point. Taking my game past the point of river running and basic belly surfing required me to tap into my friends named agility, strength and finesse.

 

Let’s Talk About Feelings

This is what I really love. I love how agile the Play 35 is. If you give it a little nudge you can go places together. The boat is designed to be stable enough to inspire confidence but with an agility derived from the advances in hull design of modern freestyle kayaks. The ample rocker allows the boat to spin and pivot with ease. I knew it had potential because on my first ride it spun me and took me places I never intended on going.  Once I made the commitment to work together with my Play 35, I was hooked.

Bellyaking on the Nantahala River

sorry for the clarity, it was taken with a flip phone

Confidence and communion with the river is something I have been able to achieve in a greater way than I ever could in my kayak. Perhaps it’s because my body covers more surface area on the water. Perhaps it’s how I”m able to respond to the river rather than just reacting to every single current that comes at me.

Going Fast Sitting Still

Nothing says New-Age spiritual like surfing a wave in a bellyak. One of my favorite pastimes is surfing at staging eddy on the Ocoee, watching creekers in full faces practice their roll in the eddy next to me. And as I write this I can’t help but laugh a little because in a few years our experience today will seem so underwhelming by the standards of what will be created tomorrow.

Like jumping curbs back in your huffy bike glory days thinking you were all that therewas in the world only to learn that mountain biking was already a thing and you were living a lie.

 

Funnercise

I have to admit I used to be a little bit of a freak about getting a workout in and I’ve always dreamt of legitimately having fun and being fit at the same time. I like ball sports but they still hurt when I’m tired, but have you heard of Bellyak Fitness? My idea of Bellyak Fitness is taking my bellyak whitewatering and playing as hard as I can only to find out when I am done that I am completely exhausted, my hip flexors are more open than that can of worms you opened when you asked your grandma how she was today, and my arms and abs feel like I’ve been on that crossfit diet. All the while I was just having fun.

 

 

Better than the local public pool

Really there’s not much I love more than river running on the bellyak which is something almost all of us can do whether it’s on class II or Class IV. I love many water sports, but the one that makes me giggle the most at the same time challenge me is bellyak. Aside from swimming, it’s the closest I have been to really being a part of the water.

Racing in the 2017 Ocoee River Rac

 

 

Being straight silly because that’s what life and sport is about