Every canoe has a story, and this 1956 Old Town Otca is no exception. The journey began with a call from Calum, a client living on the Isle of Lewis in Scotland. He told me about a canoe that had been part of his childhood memories—originally belonging to family friends, then passed on to another owner. Unfortunately, over the years, the canoe had been neglected. After purchasing it in its current state, Calum reached out to me with pictures asking me to assess the extent of the work needed.
As someone who specializes in canoe restoration and craftsmanship, I couldn’t resist diving into this beautiful project. The combination of the canoe’s history and its potential to return to its former glory was exciting. In this blog post, I’ll walk you through the restoration process of this 1956 Old Town Otca with sponsons. It’s a process of care, patience, and a little bit of humour—because, let’s face it, when you’re dealing with 70-year-old boats, there’s bound to be a few surprises along the way!
The Surprises Behind Every Canoe Refurbishment
When it comes to canoe refurbishments, there’s always a chance of encountering unexpected challenges. These surprises don’t always show themselves until you’re deep into the restoration process. And trust me, sometimes they can open a bit of a "can of worms," leading to repairs that are more complicated (and costly) than expected.
One of the things I love about working with Old Town Canoes is that if you can find the serial number, you can often trace the original build sheet from the W.C.H.A. website. Luckily, I found the number on the canoe’s stems, and after tracking down the build sheet, we confirmed the original owner’s name—a delightful surprise that Calum recognized and validated we were working on the right canoe.
Unexpected Challenges
As I assessed the canoe, I noticed the screws holding the keel and gunwales were severely corroded. They were so rusted that they risked snapping if not handled carefully and some did! which led to a delicate removal process.
The canoe also featured sponsons—float chambers that are quite rare, especially here in the UK. I wasn’t entirely sure how they were attached at first, but after some investigation, I realized most of the screws holding them in place went through the ribs inside the hull. This made sense structurally, but it also meant some screws were hidden beneath the planking, requiring me to carefully pry off the ends of the sponsons to access them. This delicate assembly would need to be refitted carefully after the main hull was re-canvassed.
Addressing Unwanted Additions
As with most restorations, I came across some “unwanted additions”—like a heavy, uncomfortable plank seat that had been bolted through the scupper slots with thick, rusted steel bolts. Removing these required a bit of cutting, but it was necessary to restore the canoe’s original integrity.
Further Investigation and Repair
After removing the plank seat and assessing the main structure, I found most of the planking to be in good condition. However, a small hole near the stem and some loose planks needed attention. The ribs were also intact, though one stem and an inwale required a small spliced repair.
The interior varnish was in rough shape, with peeling in several spots and dark marks—possibly from the corroded steel bolts. The process of stripping the varnish was slow and meticulous, as many layers had been applied over the years. But with patience, the wood started to reveal its true beauty.
Once the stripping was complete, I began addressing the seat and thwart repairs. The thwarts had large indentations from the nuts being pulled into them, so I had to rebuild those surfaces using plugs. One seat had a broken front rail, which required replacement. I carefully cut and removed the damaged parts while preserving the original joints and then fitted a new wider rail with a hole for a mast.
Restoring the Decks and Outwales
The canoe had two sets of outwales or rub rails—one on the main hull and the other on the sponsons. Both required stripping and refinishing, which I carefully completed by scraping and sanding. The decks were in decent condition but needed some minor repairs, and I carefully sanded them to preserve the original Old Town logos.
Canvassing and Sailing Rig Adjustments
Canvassing is a crucial step in restoring a wood canvas canoe. I stretched the canvas tightly around the hull, ensuring it was held in place with stainless steel staples. The process requires patience, especially when working with a canoe this long—18 feet in this case. In the past I have canvassed canoes right side up but because of its length I did this one in the inverted position on trestles.
Once the main hull was canvassed, I moved on to the sponsons. These were more intricate, as the canvas had to be stretched over and beneath them, ensuring the classic look and functionality were maintained. I sealed the seams and carefully fitted the canvas around the sponsons, just as it was done back in the day. As the eagle eyed of you you may notice I have filled the main canvas before the sponson is fitted.
Sponson canoes like this one are perfect for sailing but it was missing a sailing kit. Luckily I had one I made for another canoe that I had sold separately so I asked Calum if he would like me to modify it to fit. He agreed so I made the alterations.
Calum was excited to add the sailing rig, and it became a special part of the restoration.
Final Touches and Paintwork
Once the canvas was in place and the sponsons were secured, I moved on to the painting process. I chose Epifanes Forest Green for the topcoat, as it closely matched the original colour of the canoe. After priming and sanding, I carefully applied the paint, rubbing down between coats ensuring a smooth, durable finish.
I also created a new floor rack for the canoe, based on a design from the 1920s. This added a nice touch of authenticity and utility to the final piece. Once everything was dry, I added the final detail: the name "Susquehanna" in gold lettering on the bow, a perfect finishing touch.
The Finished Product
After a few more days of drying and final touches, the 1956 Old Town Otca with sponsons was ready for its big reveal. I sent Calum a video and he was thrilled with the results. The restoration process was thorough and rewarding.
He sent me some beautiful pictures of the canoe on the water, surrounded by the stunning scenery of the Isle of Lewis. It’s incredibly satisfying to see an old canoe return to its natural element and know that it will continue to give joy for years to come.
If you have an old canoe that needs some love—or if you’re looking for a custom-built masterpiece—I’d be thrilled to help. These canoes aren’t just boats—they’re a connection to nature, to history, and to the art of craftsmanship. Let me help you create or restore a canoe that’s as timeless as the waters it’ll glide across.
Contact me today to discuss your restoration or custom canoe project. I’d love to bring your canoe dreams to life!
Alick