The Hull Truth
The shape of a canoe hull defines its performance characteristics, and
each hull is a subtle blending of individual design elements. The hull
design begins as a concept, and each of those design elements is carefully
evaluated and then artistically blended back into the whole, becoming
a wood-strip prototype that can be paddled and tested. Although each design
is different, our goal remains the same: to ensure that each of our designs,
regardless of its final use, is the most versatile it can be.
Elements of Hull Design
The overall performance of a canoe is most affected by the length and
width of its hull. The length is the primary factor in determining potential
speed. Given two canoes of different lengths but otherwise identical specifications,
the longer canoe will be faster (and easier to paddle over distance),
while the shorter canoe will be easier to turn. Width is a primary factor
in determining stability: a wider canoe will be more stable. Here are
the other major design factors:
Cross-Section Shapes
These cross-section views are outlines of a hull as if the canoe were
sliced in two at its widest point. It provides a sense of how the canoe
will handle in terms of stability by giving the best look at what’s
going on below the waterline.
[ Shallow V ]
The shallow-V is a Mad River Canoe trademark. It offers an outstanding
combination of tracking, maneuverability, and seaworthiness—ideal
in an all-around canoe. The concept is simple: Canoes that are underway
on two opposing planes are more stable. It’s like the wings
of a soaring bird. The V-shape is not at its most stable when at
rest, but in moving water or heavy waves, it settles into its slot.
The old Viking ships were V-hulled. This is the most versatile canoe
design, and one of the most emulated. We use the Shallow-V in such
classic designs as the Explorer, Revelation, and Destiny.
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[ Broad Shallow Arch ]
The almost flat bottom of a broad shallow-arch offers exceptional
stability, maneuverability, and reasonable forward speed. This is
the most stable shape and we use it in beginner-friendly boats such
as the Tahoe and Tahoe 16.
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[ Round V ]
In this design, the V-shaped ends blend into an arch in the center.
This allows the hull to sideslip quickly and spin on a dime, while
still providing the tracking required for "must make" ferries. This
is the best shape for whitewater and you’ll see it in the
Guide and our Outrages.
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Above the Waterline
[ Flare and Tumblehome ]
The "side" of a canoe can curve in toward the center as it rises
from the waterline, or it can curve out. Flare curves out, and it
can be very helpful at the bow and stern, where it makes for a drier
ride. Tumblehome curves in, allowing a more vertical and efficient
paddle stroke. Many Mad River canoes use flare in the bow and stern
for a dry ride and tumblehome in the center for efficient paddling.
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Rocker
When viewed from the side, "rocker" is the amount of curve in the hull,
much like the rocker in a rocking chair. Rocker plays a key role in a
canoe’s maneuverability, determining in large part how it will turn.
[ No Rocker ]
A canoe with no rocker, is built for covering long distances
in a straight line. The full length of the hull is in the water,
so it tracks well and has good speed. The Horizon is a good example
of that.
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[ Slight and Moderate Rocker ]
As the rocker increases, so does the ease of turning.
The trick is to design a boat that turns and tracks. The Explorer
and Malecite, for example, have slight rocker, which (when combined
with their Shallow-V hulls) provides the balance of tracking and
turning. A longer hull with moderate rocker, like the Revelation,
also has that balance.
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[ Pronounced Rocker ]
Pronounced rocker is the realm of whitewater boats,
where turning rules. That’s why the Outrage and Outrage X
pivot with ease and spin on a dime.
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Hull Symmetry
[ Symmetrical Hull ]
When viewed from above, a symmetrical hull has its widest
point at the center of the hull and basically identical forward and aft
sections. Symmetrical hulls are predictable, seaworthy, and versatile—it’s
a classic practice for solo paddlers to paddle tandem canoes backwards,
sitting in the bow seat facing "backwards." It’s another reason
the Explorer is one of the most versatile canoes you can own.
[ Asymmetrical Hull ]
These designs feature different forward and aft sections: Swede-form
has the widest section aft of centerline, creating a longer bow and producing
enhanced forward speed and tracking. It is often used on touring canoes,
such as the Horizon.
Fish-form has the widest section forward of the centerline, producing
a buoyant bow, ideal for paddling upstream and rising over large waves.
It is common in whitewater canoes, such as the Outrage.
The Hidden Features
We pride ourselves on building exceptional canoes but many of the features
we incorporate in each canoe are hidden…
Gunwales
Since these form the frame that supports the hull, they must be stiff,
strong and weather resistant. We use three different gunwale systems,
and most canoes are available in two gunwale trims:
[ Northern Vermont White Ash Gunwales ]
Each pair of inwales and outwales is grain-matched, numbered, dipped
in Gunwale Guard (our specially-formulated, deep-penetrating, anti-fungal
wood finish), and air-dried. Every gunwale is cut by hand to use the best
grain–no knots, swirls, or short grain across the gunwales—increasing
flexibility for top performance and long life. This is our strongest gunwale
system, and is the easiest to repair in the field. Wood gunwales require
more maintenance and special storage in cold climates when mounted to
Royalex canoes.
[ Vinyl Gunwales ]
An extruded vinyl sheath with 6063-T5 aluminum inserts, these gunwales
rival wood for strength and require no special care or maintenance. They
are very durable but are not as easy to repair in the field as wood.
[ Powder-coated Aluminum Gunwales ]
Lightweight and low maintenance, these are intended for lighter weight,
quiet water canoes.
Hardware
All hardware used by Mad River Canoe–bolts, machine screws, and
gunwale screws—is stainless steel, which offers superior strength
and corrosion resistance. (On vinyl and aluminum gunwales, we use anodized
aluminum rivets, colored to match the gunwales.)
[ Seats, Thwarts and Yokes ]
Hardwood seat trusses complement the canoe’s good looks while providing
structural rigidity. Native New England butternut is used in the two-piece
hardwood decks with a finger joint that is stronger than the wood itself—without
using rain forest products. Standard hand-crafted ash-framed seats with
cane inserts are cool, quick drying, comfortable and quite handsome; contoured
cane seats are optional. (Optional web seats provide maintenance-free
durability and unsurpassed strength.) Every canoe is hand-balanced prior
to the installation of our standard ash yoke to enhance portaging comfort.
Construction
All of our boats, regardless of construction technique, feature extra
reinforcing in critical areas. In our Royalex® canoes, the bow, stern,
center section, and keel line are reinforced for unmatched durability
and stiffness. In our composite canoes, specially engineered resins maximize
durability and stiffness, while extra layers of fabric and graphite reinforce
critical wear and impact areas. Optional integral Kevlar® skid plates
with graphite filled resin increase durability without compromising paddling
efficiency or appearance.
Warranty
Every Mad River Canoe undergoes an exhaustive multi-step quality assurance
process during manufacturing; only after passing this test does the completed
boat receive its Confident Rabbit logo, Mad River Canoe name, and signed
Quality Assurance card. And, of course, there’s our Lifetime Warranty.
We proudly stand behind our products.
Although many of these components are hidden from your view, they all
reflect our commitment to building the best canoes with the best materials.
When combined with our innovative designs and state-of-the-art manufacturing
techniques, it’s easy to see why we say that excellence by design
is no accident. It’s our way of life.
Hull Materials
No other manufacturer can match Mad River’s ability to craft high-tech
materials into timeless designs with outstanding performance. Each of
our construction techniques has unique advantages, and the simplest way
to approach the complex question of selecting the right material is to
determine where or how you will paddle. There are other factors to consider,
such as weight and price, but being honest with yourself about where and
how you paddle is the best place to start. Rest assured that whichever
Mad River Canoe you buy, you’re buying the best.
Roto-molded
Polyethylene (R Series)
Mad River introduced this new level of quality and affordability to canoeing
in 2000. In our TripleTough™ construction, polyethylene powders
are precisely loaded into computer controlled rotational-molding ovens.
The powders are melted within the mold and oven rotations are timed and
measured by sophisticated computer-driven programs to place just the right
amount of materials and reinforcement where they are needed. The result
is a three-layered skin-foam-skin hull that’s tough, recyclable
and impact-resistant.
Usage: Day cruising, sporting, quiet water touring, river touring.
Advantages: Affordable, stiff, strong, impact resistant.
Bottom Line: True canoe performance, most affordable Mad River Canoe
material.
Construction
A three layer rotomolded construction consisting of:
- Inner and outer layers of high density linear polyethylene for
durability and impact resistance.
- Sealed closed-cell foam inner core layer for stiffness and flotation.
- Variations in mold surface temperature increase hull thickness
in high impact areas.
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Advantages
- Perfect entry level recreation boat - inexpensive, safe and
stable with lots of flotation.
- Very durable and long lasting.
- Very low maintenance.
- Less expensive than Royalex®.
- Quieter to paddle than aluminum.
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Mad River versus the Competition
- Advanced molding techniques put more material in the high impact
areas and less in the low impact areas, resulting in a lighter
and stiffer hull.
- Shallow V hull design enhances hull stiffness for improved paddling
performance - it paddles like a Mad River, not a barge!
- Full length aluminum insert in gunwales for added torsional
rigidity.
- Molded-in graphics won't peel or scratch off like decals.
- Webbed seats in solid ash frames are lighter and more attractive
than rotomolded bucket seats.
- Environmentally friendlier manufacturing process than crosslinked
polyethylene - no harmful formaldehyde gas emitted during molding.
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Royalex®
(RX)
The gold standard for rugged all-around canoes. Royalex® sheets are custom-made
in a process that combines sheets of vinyl, ABS, and foam and then vulcanizes
them together. The Royalex® sheet is then thermo-formed (with heat and
vacuum) in a mold to create a hull with outstanding strength, internal
flotation and a tough and slippery vinyl skin. It’s lighter than
roto-molded polyethylene, far quieter and "warmer" than aluminum, and
virtually maintenance free. Each canoe’s sheet construction is different;
the exact placement of reinforcing ABS and foam reflects the requirements
of that model. Certain models intended for quiet-water use a lighter weight
sheet for easier portaging. Note: Our Royalex® is not the same as other
canoe manufacturers’. You may notice that our canoes tend to be
a little heavier than the competition, because we elect to place more
reinforcing material into our Royalex® for a more durable canoe. That’s
one of the reasons we are able to offer our lifetime warranty to original
purchasers.

Usage: All categories (may depend on construction--see
model descriptions).
Advantages: Durable, quiet, comfortable, low maintenance,
extremely tough, great value.
Bottom Line: For whitewater and demanding conditions, this is the material
of choice. The lighter version is just as abrasion-resistant, quiet, and
comfortable, but not as tough over time when used hard.
Construction
A vulcanized sandwich construction consisting of:
- Pigmented vinyl inner and outer skin for UV protection and abrasion
resistance
- ABS (Acrylonitrile butadiene styrene) substrate layers for impact
resistance and stiffness
- ABS foam inner core for structural rigidity and flotation
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Advantages
- More durable and less maintenance than Kevlar® and
fiberglass
- Lighter than polyethylene
- Quieter to paddle than aluminum
- Less expensive than Kevlar
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Mad River versus the Competition
- New state-of-the-art molding facility ensures consistent high
quality — no weak spots from overheating or overstretching
sheet during forming.
- Thicker substrate layers and more foam core increase durability
and stiffness with little additional weight (see the difference
by looking at hull thickness between wood gunwales).
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K-Glass
(KG)
K-Glass is a hybrid laminate combining the tensile strength of Kevlar®
and the rigidity of fiberglass: durable, extremely efficient and more
affordable than all-Kevlar® construction. We modeled this on our proven
Kevlar® Expedition lay-up and substituted select fiberglass internal layers
to reduce cost without sacrificing performance. Features include Kevlar®
and fiberglass keel line patches, a custom-formulated vinylester resin,
full inner and outer layers of Kevlar® and Kevlar® reinforcing in critical
wear areas. There is more Kevlar® in a Mad River Canoe KG construction
than most of our competitors "all" Kevlar® canoes.

Usage: Quiet Water Touring, Day Cruising, Sporting, and Moving Water
(mild).
Advantages: Finer entry and exit lines than Royalex®, much more durable
and lighter than all-fiberglass construction; produces fast, rigid canoes
with great response, stiffness and speed.
Bottom Line: Great construction and good value for canoes used mainly
in quiet water.
Construction
A handcrafted wet laminate consisting of:
- Outer surface of durable gel coat resin for abrasion resistance
and UV protection.
- Two full inner and outer layers of Kevlar cloth
- Multiple layers of Kevlar reinforcing end patches in critical
wear areas.
- Kevlar and fiberglass keel line patches for added stiffness
and durability.
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Advantages
- Lighter and more efficient to paddle than Royalex®
or polyethylene.
- Lighter and more durable than fiberglass
- Less expensive than Kevlar with similar performance.
- Intermediate price point between Royalex and Kevlar.
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Mad River versus the Competition
- More Kevlar® than any other hybrid construction.
- Full inner and outer layers of Kevlar provide greater tensile
strength than fiberglass.
- Additional Kevlar reinforcing patches in all critical wear areas.
- Custom formulated vinylester resin provides better balance of
stiffness and flexibility than polyester resin.
- Graphite tape and wound Kevlar fiber “rope” are
laminated into the bow and stern of hull for greatest impact resistance
on the market.
- Available with optional molded-in integral skid plate of carbon-impregnated
Kevlar felt for enhanced durability and abrasion resistance.
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Kevlar®
Expedition (KE)
All Cloth
Our most durable composite. Using layers of Kevlar® we get a light, extraordinarily
tough hull. We specify the weave and surface finish of our Kevlar® fabric
and carefully match it to a proprietary vinylester resin for added resistance
to impacts. Up to 11 layers of Kevlar® are used in our lay-ups. The gel
coat outer surface adds protection and beauty.

Airex™
In our large Kevlar® expedition canoes, we use an Airex™ foam core
and ribs with the Kevlar®. This allows us to make an expedition-caliber
canoe that is much lighter and stiffer than all-cloth construction. Airex™
has significantly better shear strength and impact resistance than other
foam-core materials.

Usage: Day Cruising, Quiet Water Touring, River Touring, and Sporting
Advantages: Like K-Glass, Kevlar® Expedition produces much finer entry
and exit lines than Royalex®, and it’s far lighter than Royalex®
and lighter and tougher than K-Glass, resulting in light, fast boats with
great response and good stiffness.
Bottom Line: This is the perfect material—light and strong—for
a canoe-touring hull.
Constructionhandcrafted wet laminate consisting of:
- Outer surface of durable gel coat resin
for abrasion resistance and UV protection.
- Three full layers of Kevlar cloth.
- Multiple layers of Kevlar reinforcing end
patches in critical wear areas.
- Multiple Kevlar keel line patches for added
stiffness and durability.
- Multiple internal Kevlar belly layers for
stiffness.
- Low elongation vinylester resin provides
stiffness to balance Kevlar's flexibility.
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Advantages
- Much lighter and more efficient to paddle
than Royalex® or polyethylene
- Lighter, more flexible, and more durable
than fiberglass
- Best strength to weight ratio of all available
materials
- The choice for expeditions!
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Mad River versus the Competition
- More Kevlar than any other all-Kevlar construction — up
to 11 layers in high wear and impact areas!
- Additional Kevlar reinforcing patches in all critical wear areas.
- Custom formulated vinylester resin provides better balance of
stiffness and flexibility than polyester resin.
- Graphite tape and wound Kevlar fiber “rope” are
laminated into the bow and stern of hull for greatest impact resistance
of any lightweight on the market.
- Available with optional molded-in integral skid plate of carbon-impregnated
Kevlar felt for enhanced durability and abrasion resistance.
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Kevlar®
Lite (KL)
This extremely lightweight construction features Airex™ foam reinforcement
and a skin coat of pigmented resin, reducing hull weight by up to 20 percent
when compared to Kevlar® Expedition. By using Airex™ and an S-glass
outer layer, we are able to offer a superior construction, with better
abrasion resistance and better impact tolerance than any other lightweight
on the market.

Advantages: Our lightest hulls – extremely efficient and very stiff.
Bottom Line: The only choice if light weight matters above all else;
best suited to deep water.
Construction
A handcrafted vacuum-assisted laminate consisting of:
- Outer layer of S-glass fiberglass for better abrasion resistance.
- Two full layers and one belly layer of Kevlar® cloth.
- Multiple layers of Kevlar reinforcing patches in critical wear
areas.
- Internal fiberglass layer for stiffness.
- Airex closed cell linear crosslinked foam core (and side ribs
in longer models).
- High elongation vinylester resin.
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Advantages
- Stiffer and lighter than all — Kevlar® constructions
- Lighter and more durable than fiberglass
- Best strength to weight ratio of all available materials
- Easy to car-top and portage
- The ultimate in lightweight performance!
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Mad River versus the Competition
- S-glass outer layer is more abrasion resistant than Kevlar®
outer layer in competitors lightweight fabrications.
- Airex foam core is more flexible than Divinicell or Clegicell
linear cores used by other manufacturers — greater impact
resistance.
- Additional Kevlar reinforcing patches in all critical wear areas.
- High elongation vinylester resin provides more flexibility to
balance stiffness of foam core.
- Graphite tape and wound Kevlar fiber “rope” are
laminated into the bow and stern of hull for greatest impact resistance
of any lightweight on the market.
- Optional pigmented resin skin coat offers better UV resistance
than clear coats.
- Available with optional molded-in integral skid plate of carbon-impregnated
Kevlar felt for enhanced durability and abrasion resistance.
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