Reading my posting from yesterday again, it gave me some inspiration for further investigation.
Simply using the keywords “thermoform, kayak, ABS” opened another world of information.
On the contrary with my conclusion yesterday, I can say now that the use of thermoforming for seakayaks might be new. But for canoes and other kayaks or watercraft it is already in use for approx. 10 years.
The ABS-material was first used for canoes; probably the easiest approach because it is not necessary for an open canoe to make a hull-deck-connection.
Quite a lot of names for the material can be found: Royalex and Carbonlite 2000 being well known ones. Airalite is just another name for the same type of material. Probably just with other composition and characteristics.
Apart from the issues I considered to be critical, I found another care-point: the advise to use a UV-protector. To be applied 4 times a year to protect the material from degrading in the sunlight.
About the glue, that I described as essential, I also found out that there are perfect glues for the purpose of gluing deck and hull together.
What to think of : 3M 5200 Sealant/Adhesive
This glue is said to be well known in the marine industry for its adhesive qualities.
“[The 5200 creates a particularly superior bond with ABS plastic. This makes it a good choice for Royalex canoes and thermoform plastic.”]
With this information I feel a little bit more comfortable now.
Although thermoformed boats are produced for years the remark that I found “[However, like all thermoform plastic ABS loses its plasticizers with age and becomes increasingly brittle]” gave me something to think about.
Probably manufacturers solved this and preventing the brittleness must be the secret.
Anyhow keep it in mind.
Finally: at
www.wavelengthmagazine.com/2005/dj05kid.html
I found an interesting article about the production of thermoformed kayaks. It shows also the big machines, necessary to produce them.
{sorry to inform you: okt. 2021 this article does not exsist anymore but you can still find wavenlength magazine at: https://paddlingmag.com/}