PolySail International

High Performance/Low Cost Sails for Small Sailboats




Evolution of the Z-PDR (A Class Racing Version of the PDRacer)


Ryan Gray pilots the Z-PDR back to shore after her first test run. Note the angle of the kick-up

leeboard  as he powers into the sandy shore of the Intercoastal Waterway near Port St. Lucie, Florida.


Most early Puddle Duck Racers, or PDR’s as they are known, had a fairly boxy profile based on the basic hull requirements drawn up by David “Shorty” Routh, the ceator of this US Sailing certified racing class. Routh’s class requirements were fairly simple for this 4’ x 8’ scow assuring that the bottom 10” of these boats would have the same defined hull shape. (See the class rules at http://pdracer.com/ ) Above the 10” defined hull section, however, the individual PDR builder/designer had free reign. The creativity of design this “open” concept allows has made the PDRacer one of the fastest growing small boat classes in the world.


Our first PDR Hull #100 Lame Duck was typical of these early PDR’s. Below is a photo that shows Lame Duck in the foreground and two of four other PDR’s that I helped others to build.


The 2008 Lake Vista/Hoosier Regatta. “Lame Duck” is the boat in the foreground.

Five PDRs participated in the race. All had their hulls built in my workshop.


Although some of these boats carried different sails, most of the hulls were substantially alike on the exterior. Freeboard was about 15 ½” to 16”, bottoms were ¼” 5-ply underlayment nailed to cedar chines cut to the rocker of the bottom, and leeboards and rudders were made to kick up for sailing in Indiana’s shallow lakes. One major difference was in the sail plans. While Lame Duck and another boat carried the 60 sq. ft. Bolger leg’ o’ mutton sail, two other boats carried a 75 sq. ft. lateen and a 55 sq. ft. balanced lug sail according to the owners’ preferences. The building plan and instructions for Lame Duck are outlined in an article I wrote earlier called Camp Sailboat which is posted on my web site at: http://www.polysail.com/Camp%20Sailboat.htm


One change that we began to incorporate after Lame Duck was building the sides with the frames already attached rather than building the entire framework and then attaching the sides. A second innovation that I tried on Tom Heiser’s  #223 Amakusa Duck was to construct the Styrofoam flotation as a single removable unit supporting a one-piece deck instead of just filling in the side frames with foam and adding 2” of extra flotation around the inside of the boat. The initial flotation unit was built from a single 4’ x 8’ sheet of 2” thick Styrofoam. The basic premise behind the insert was that with the foam placed up under the deck, there would be more flotation in that area, and if the boat were knocked down, the boat would float higher and little to no water would be shipped over the decks. The foam insert concept was carried over to the Z-PDR, and subsequent flotation tests validated that theory. The plans and pictures for that Styrofoam insert for Tom’s boat are shown below. For the Z-PDR the insert height was cut down to 11.75 inches and curved to fit the shape of the sides and bottom. Consequently, the shaped Styrofoam provided even more support for the decks on the Z-PDR.




The last two photos show the completed Syrofoam insert alongside the nearly completed hull.








Tom Heiser of Muncie, Indiana, sails his lateen-rigged Amakusa Duck in the 2008 Hoosier Regatta. Tom’s hull was the first to have a one-piece Styrofoam insert under the decks.


Wild Duck, hull # 143, was constructed in an attempt to establish a new PDR world record for the amount of sail carried. At the same time, I wanted Wild Duck to carry a rig that would allow her to be sailed wing on wing downwind for more speed. While the hull was similar to other PDRs I had built, the bow featured a deck and mast steps to support up to three masts and sails.


I first sailed Wild Duck at the 2007 Midwest Messabout hosted by Jim Michalak at Rend Lake, Illinois. Under her twin 52 sq. ft. Leg O’ Mutton sails, she proved very speedy in light winds. The 104 sq. ft. biplane rig also proved responsive in nearly all points of sail with the one sail blanketing the other only when sailed at right angles to the apparent wind.


I tested Wild Duck with various sail combinations and found that, with her port-side-mounted leeboard, she was most easily controlled with a single sail up in either the port or center mast position. With a single sail up on the starboard side, the helm was unpredictable. In 2008, I combined her 104 sq. ft. biplane rig with a 60 sq. ft. leg o’ mutton sail to set a world record for the amount of sail carried on a PDR.







Testing Wild Duck’s biplane rig

This photo taken at Rend Lake by Jim Michalak is featured in the PolySail International slogan “Buy low; live slow; sail fast!”

Wild Duck setting a PDR world record of 164 sq. ft. of sail carried.

I considered setting the Z-PDR up for a biplane rig as well, but I was afraid that with only about 6” of mast bury, she could not support two large sails. However, the large sail concept was not abandoned for the Z-PDR. Besides her 58 sq. ft. sailboard-type sail that she carried on her first test, the Z-PDR can hoist a 100 sq. ft. balanced lug or an 85 sq. ft. leg o’ mutton sail on her extendable aluminum and bamboo mast.


During the winter of 2007-2008, after discussing participating in the Texas 200 with John Nystrom of Peru, IN who sails hull # 134 John Duck, I began construction of yet another PDR. The concept  drawings showed a cabin approach, but this was later changed as it became clear that my community college teaching schedule would not allow me to participate in the five-day, 200 mile Texas event. The boat that emerged did have some unique features, however, including:

·         An all Styrofoam, fiberglass covered bottom;

·         A roll-up cuddy cabin made from polytarp and sail window material;

·         Add-on exterior Styrofoam panels to make the boat class legal.

This last add-on feature led my 6 year-old grandson to dub Webfoot hull # 199 the “Transformer Boat”, after his favorite movie at that time.

Webfoot concept

Initial drawing and cardboard mockup

Bottom, showing extensions for mounting sides to make the boat class legal

Webfoot goes 3-D. Assigned hull # 199. Note add-on sides

Interior completed. Weight 54 lbs.

Webfoot awaits float tests on Lake Vista

Canopy extended

Wind pushes the lightweight Webfoot along at a comfortable pace. Canopy acts like a small spinnaker downwind.

This is the only picture I could find of Webfoot under sail with her sides on. The sail shown here was only 34 sq. ft. but pushed the boat along nicely.


Webfoot was completed early in the summer of 2008 just in time for the first Hoosier Regatta. However, no one was available to sail her in the race itself. She was sold in the fall of 2008 shortly before we moved to Florida.


With Webfoot I began pushing the envelope on light weight hulls and cabin structure. I had used the Styrofoam bottom previously in a 4’ x 8’ scow that was one of five boats in the Hot Tub series I had built. (See this account at http://www.polysail.com/boatnote.htm ) Boats of this size with a 2” Styrofoam bottom float high even when loaded and will continue to float even with a substantial hole in the bottom. However, the bottoms are easily damaged and are not easily shaped to the extreme stern rocker of the PDRacer. The flat run of the Hot Tub scows, on the other hand, are more suited for the lightweight foam bottoms. Although Webfoot’s hull was lightweight, the aluminum mast and wood kickup rudder and leeboard added considerable weight to the structure. All would need to be redesigned for the Z-PDR.


In designing Webfoot’s canopy/cabin, I was faced with the question of how to support the structure without much weight. I solved that problem by incorporating two mahogany lathe arches on either side of the boat. These arches, in turn, supported two crosspieces and the polytarp canopy. Each arch was made up of two 3/16” thick x 2” wide lathing strips that were glued together while arched. The resulting arches were incredibly strong for their weight and would support the entire hull when turned upside down. I could also lift the boat by grasping the extended handles on one of the cross pieces. The strength and rigidity the arches added to this boat led me to slightly arch the deck of the Z-PDR both bow to stern and gunwale to gunwale. Those arches helped solve one of the primary problems with the rectangular structures of the PDRacers—making the hull rigid.


Other features of Webfoot that found their way into the Z-PDR design were the low freeboard and extended bow concept. On Webfoot the bow transom is extended above the deck by about 5” and supported on either side by pieces that were left over from cutting the bow rocker from the 1” x 8” x 8’ cedar board that forms the bottom chine. On the Z-PDR, instead of being in line with the sides, these pieces were angled inward toward the bow, to both support the bow transom extension and to support the mast partner. (See the photos below.)


Diagram shows how the piece removed from the frame to form the bow rocker was reused to support the bow transom.

Angling these bow support pieces across the deck helps strengthen the boat’s structure.


One of the new features of the Z-PDR is a kick-up rudder that is both attractive and functional. The case and tiller are one piece and designed so that the outline continues the rocker, then curves back to form the tiller. A single bolt holds the rudder in place in the case, and a single length of shock cord holds the rudder in the down position or, when the rudder is lifted slightly, elevates the rudder high out of the water. Tightening the wing nut pinches the sides of the case together and holds the rudder firmly in place. This rudder case is a much more pleasing and functional design than I have seen on most small boats, and it particularly suits the low profile of the Z-PDR.



Rudder in the up position

Rudder in the down position

Case fitted to the stern transom

I designed Z to be a racing PDR, so the cockpit is bare bones and the ride will probably be wet. I coated the floor in the stern half with a sand finish paint for traction when moving from side deck to side deck. It is intended to be a “sit on” hull, not a “sit in” hull. A hiking plank across the decks is not out of the question.


To optimize her for racing, Z-PDR will have multiple sail, mast, and leeboard options. Currently, I have four sail options: A 58 sq. ft. battened sailboard-type sail, a 65 sq. ft. leg o’ mutton, an 85 sq. ft. leg o’ mutton, and a 100 sq. ft. high aspect balanced lug sail. Each sail has its own mast requirements, but by using a sectional mast, the mast length can be extended from 15’ to 18’ 6”. The basic 15’ mast has two 4’ aluminum sections and one 8’ bamboo section. This mast weighs in at just over 7 lb. and will float. This mast can be used for three of the four sails. If all goes as planned, only the 85 sq. ft. leg o’ mutton with its 17’ + luff will require the additional 4’ aluminum extension.


Four leeboards may also be available for the Z-PDR. One of the larger ones will have to be used on Wild Duck, but the others can be used at will. Three of the four boards are asymmetrical, while one is symmetrical and weighted. “Fat Bastard” is a short, nearly square board that will put over 440 sq. inches down in the water with a total length of only about three feet. On the other hand, the Big A… asymetrical Board is nearly as tall as I am, but with its hollow core is very lightweight. One thing that hasn’t changed much is my preference for a leeboard over a dagger board or center board. Once you build a trunk, it’s not easy to change boards except to make one longer or shorter.


Leeboard selection for the Z. “Fat Bastard” is the unpainted cedar board with the slot.


The Z-PDR awaits further testing at the Worlds in October. Skids and a seat might be in her future if she fails to perform as a racing PDR.


November 2009 Update


The 2009 World Championship race at Allatoona Lake, Georgia, was to be held on Saturday morning, October 16. I planned to arrive early on Thursday morning in order to do some final testing of both the Z-PDR and Wild Duck, the boat I planned to sail which hadn’t been in the water for over a year. The week leading up to the race, however, almost ruined those plans.


On Monday, October 5, my son and I trailered the Z-PDR out to Hutchison Island, not far from our home in Port St. Lucie, Florida, to try to get in a second test of the boat prior to the Worlds. Earlier, we had selected a spot for testing along the Intercoastal Waterway known as the Indian River Lagoon that was somewhat sheltered from the strong onshore Atlantic Ocean winds by the narrow barrier island. We hoped to try out a slightly larger 65 sq. ft. leg o’ mutton sail with the mast extension in place. As Ryan launched the Z, however, we observed storm clouds moving in from the southeast and the breeze beginning to kick up small waves. It quickly became clear that the sprit boom had been mounted too high on a loose snotter and was not doing its job of forcing out the clew. Instead, it began thrashing badly each time Ryan attempted to turn back toward shore. As the wind increased, the boom finally crashed against the mast and broke. Ryan quickly grabbed the pieces and tossed them into the boat, then managed to catch the clew and sail loose-footed in towards shore about a quarter-mile upwind of the launch point. Unfortunately, that area had a number of isolated rocks near the shoreline, and one of these holed the hull as he surfed to shore. Test two clearly showed the need for careful rigging and for strengthening the bottom, but the results were certainly not what we were hoping for. As luck would have it, that was the last time the Z-PDR was to touch the water until the World Championship races on Saturday.


Tuesday, Wednesday, and even part of Thursday morning were given over to repairs on both boats instead of beginning the loading process. I added two skids, repaired the hull, and epoxied the boom back together on the Z-PDR. Wild Duck got some repairs to her mast steps, gunwales, and stern, as well as some touch ups to the paint job. As a result, I arrived at the campground at Lake Allatoona at 2:30 a.m. on Friday morning. A detailed account of this preparation and the events surrounding the race itself are on my website at http://www.polysail.com/PDRWorlds.htm


Rigging Wild Duck. On  the left is John Wright’s lightweight PDR with the oval sail. The Z-PDR is in the middle. (Tim Cleary Photo)

Ryan launches for the start of race #1. The starting buoy and boat can be seen in the background. (This photo and all the following photos in this table courtesy of Ruth Leber)

Ryan leads a pack off the line in race #1. Notice the variety of sail types.

Wild Duck was performing well downwind, but I had already lost a half lap to the Z-PDR and the Bloody Splinter in the background

Ryan leads Australian legend and designer of the OZ PDRs Michael Storer on a run downwind. Eventual winner Shawn Payment is in the red boat in the background.

Ryan pulls the Z ashore after an exhausting day of three races.

Here’s a good look at the 58 sq. ft. sailboard-type sail with its sprit boom and small sprit spar. Ryan needs to be forward a bit to balance the Z



In the end, the Z-PDR probably did about as well as could be expected with so little testing. Since we had only successfully tested one sail, we decided to use the small 58 sq. ft. sail for the races. A sail of this size was a decided handicap against many of the sails that approached 90 sq. ft., but the sail, design, and sailing skills of my son held up well against the competition, placing 4th against 13 other  boats. Ryan might have placed higher still, if I hadn’t asked him to help me out of a bad anchorage at the start of the third race. Even though he ran back to launch his boat, he was unable to get to the starting line in time for the horn. Consequently, the Z-PDR started race three at the back of the pack and never fully recovered since that race was only one lap. Wild Duck, on the other hand, was a disappointment, finishing 10th overall. As a result of a misplaced board, turns invariably ended with the boat in irons, and her 104 sq. ft. of sail area could not make up for that problem on fast downwind runs.


Update, Summer 2010: Z-Duck Kits Appear at the Wooden Boat Show


Just before the deadline of May 15, I responded to a request from Carl Cramer, publisher of Wooden Boat, to bring PDRacer Kits to the Family Boatbuilding Event at the Wooden Boat Show in Mystic, Connecticut. The event was scheduled for the weekend of June 25-27 and the kits would have to be assembled on the premises in two and one-half days and launched on Sunday. I committed to bring at least one PDRacer Kit to the event because I thought that the PDRacer needed to have more exposure with traditional wooden boat enthusiasts and the national audience that this show would draw. Besides, I wanted to introduce PolySails to the New England crowd.


According to Carl, all I needed to do was provide a little information on the kit and price it then he would take care of the rest. Since I didn’t have any kits yet, I sent him a picture of the Z-PDR and told him that this would be the boat kit we would be offering and provided him with a price of $450.00 for the kit. Carl responded that he thought the price was too low, but he was confident that we would attract buyers for the kits. I spent the next few hours trying to figure potential expenses, and finally came to the conclusion that he was absolutely right. If the kit were to be built with quality wood, boatbuilding foam, stainless screws and hardware, and then epoxied at the show, the expenses would run well beyond my initial guesstimate. Not only that, but I would have 2600 miles and five days of travel expenses to factor in. I planned to email Carl the next morning to raise the price by $200 and provide him with an ad before he put out his first “blast” email to “39,000 of his closest friends.” Unfortunately, the blast email went out with copy written by one of Carl’s staffers before I could respond.  Damage control took the form of a hurriedly assembled “Z-Duck Kit Information Page” on my website at http://www.polysail.com/Z-Duck%20Kit.htm and a “Z-Duck Kit Brochure” that listed a marine plywood option for $550. http://www.polysail.com/Z-Duck%20Kit%20Brochure.htm (This page initially appears blank, but scroll down and you will see the brochure.) Later that same day, a lady by the name of Carol Roffly emailed me to say she would like to build one of my kits at the show. I was elated when she also said that she would like to build the marine plywood option.


Because Carol’s email was the only one received from Carl’s first email blast, I considered pulling out. I thought one kit in the face of several being built by other well-known boatbuilders might look a little pathetic and cast the PDRacers and PolySail in a bad light.  In the end, though, I decided that decision would be irresponsible, so I set about putting together the first Z-Duck Kit using a rough sketch, templates of the designated hull sides, and other components, that I’d kept from previous builds after first checking to see if they matched the new, closer tolerances that were just being published by David “Shorty” Routh, the designer of the PDRacer. In fact, since the new tolerances had not yet been published, I decided to work on the sail, mast, sprit boom, rudder, and other components before starting the sides and transoms. Later, I decided to continue with the hull because the templates were off less than ½” from the original designated hull requirements, and I didn’t expect them to be tightened much more than that if Shorty wanted novices to continue building PDRacers.


Several problems presented themselves immediately: May and June are my busiest months in terms of constructing sails and selling sail kits and this was an altogether new initiative. I was about to be a grandfather again and I was babysitting my granddaughter while my son was at work because my daughter-in-law had been prescribed bed rest. I had never been to the Wooden Boat Show before and I was set up to build sails, not kits. My woodworking equipment is not very extensive. My tablesaw, for example, disappeared in the move from Indiana to Florida. Would I have time to ready plans and instructions along with the kit components? How would I know that all the pieces would fit once I got to the show? How should I package all the components? Would we have time to put all the pieces together at the show itself? What were the logistics going to look like? Ultimately, I decided to go ahead and build the boat and hold it together temporarily with screws so that the hull could be disassembled and glued at the show. That way I would know that all the pieces were going to fit and that the hull could be assembled quickly enough to launch on Sunday. The photos below show the assembly process.


The mast and sprit boom were among the first pieces I completed.

Carol wanted a red-trimmed leg o’ mutton sail.

Here’s a view of the cedar framing backing up the 4mm Meranti sides. I wanted the kit components to be substantial, but light.

Here the frame has been completed and a temporary spreader inserted in preparation for screwing on the 6 mm, 5 ply, Okoume bottom.

The bottom is screwed on.

Next, the foam support pieces are added. I don’t like cutting foam, but I like it for its lightness, flotation, and for the stiffness it adds to the boat.

The deck support piece is dropped in to finish off the foam insert.  Later, an additional 3” of foam was added to each side for further support.

Two more components are cut and readied—the wishbone rudder case and the leeboard. Both of these boards were smaller than the ones carried by the original Z-PDR.

Finally, the keelson, deck, bow transom and mast partner support pieces are fitted onto Kit #1. Note the fender washers protecting the wood surface from the screws holding on the stern transom.


By the end of the first week of June, my grandson had been born and my routine was back to normal. I felt that I had the single kit project pretty well in hand. I had managed to keep up with most sail and sail kit orders, and the Z-Duck Kit had only a few days’ work to be finished. Then Carl Cramer emailed me to let me know that he was planning another email blast, and he wondered whether I could put together more kits. After a moment of indecision, I told him that I thought I could get one more ready by the show, but that there was no way I could do more than that. That seemed to satisfy him, but I was feeling very apprehensive. A couple of days later, the blast went out and I received another order, this time from a husband and wife team named Dean and Susan Herring from North Carolina for the basic $450 kit. My work was cut out for me.


I had two sides already cut to the pattern of the original Z-PDR, so to save time I decided to go ahead and use them. These sides had the slightly curved sheer of the original whereas Kit #1 had the straight sheer of the rough drawing I used for guidance. Although the boats would not be exactly alike, I wasn’t too concerned based upon their potential use. Carol planned to use hers for cruising so the slightly higher bow and stern would be an advantage for her. Dean thought he might do a little racing with his hull, so a little additional weight lost in the bow and stern would not be missed.


The preparation of Kit #2 became a race against time. I put off building sails for nearly all of June, while I worked hard to complete the kits and prepare for the 1300-mile trip to Connecticut from South Florida. To cut back on lumberyard runs and other interruptions, I tended to use what I had on hand. Thus, while Kit #2 was supposed to be a lumberyard version of the PDRacer, Dean and Susan’s boat shared many of the marine ply components of Carol’s hull. Probably the only non-marine pieces were the lauan sides that lacked a stamp.


June 20. Checking the step angle of Kit #2 for verticality

Checking the fit of the deck cover at the transoms.

Making certain that the mast fits. My son’s trailer sits in the background.

June 21. Sorting out all I needed to take with me. I left the next day.

June 24. Safe arrival in Mystic Seaport where I met Dean and Susan Herring.



As I was packing to leave, I found that I didn’t have a sail for Kit #2. I thought I had an additional Leg o’ Mutton sail with red trim in inventory, but it must have been sold. Fortunately, I had a leg o’ mutton blank sewed up that lacked only trim and grommets. I quickly trimmed it, stitched up the corners, added the grommets, and packed the sail up with its rigging kit in a plastic bag. Three days later, I rolled into the grounds of the Mystic Museum to park the contents of my trailer and Honda CRV at the family boatbuilding site at the north end of the extensive Seaport grounds. I was immediately intimidated by the big name vendors, gorgeous boats, and historical significance of the seaport. Tomorrow, our little 4’ x 8’ scows would have to compete for the crowd’s attention with boats designed by some of the best known names in the world of wooden boats.


As it turned out, Carl had blessed us with one of the best locations possible, just inside the North admission gate. Nearly anyone who entered that gate had to come past our temporary boatbuilding spot. We shared the site with a kit company from the State of Washington who apparently had one customer, and with a unit of the Boston Public Schools that taught boatbuilding as part of its curriculum. Their students lost interest quickly, so they were usually there for only about four mid-day hours. We were apparently the only sailboats in the Family Boatbuilding event. The one sailboat that was of similar size called the Nano 2.6, which looked like a surefire attraction, either did not muster a single order or the owner had a family crisis that prevented him from participating. I was truly surprised by the lack of participation in the event, but as I later came to understand, this was Carl’s first attempt at reviving this part of the Wooden Boat Show after it had languished for a few years.


Our time at the event went quickly. Our building teams generally worked from 8:00 am until 5:00 each day except the last. Each of our kit builders contributed a popup shelter, and my friend from New Hampshire Nate Carey was an able co-instructor who selflessly donated his time and tools to the cause. I, on the other hand, seemed to spend more time explaining PDRacers to interested spectators than providing direction to the building teams. I quickly exhausted my supply of PDRacer brochures and resorted to using a poster/collage I had put together in the motels on my three-day journey north to illustrate my spiel. Famous designers such as Dudley Dix and Harry Bryan stopped by; Carl regularly checked on our progress and provided added encouragement. “Two kits this year,” he exclaimed. “Next year, fourteen! We’ll have to put you in that field over there.” He was consistently very positive.


On launch day the kit boats were epoxied, rigged, and ready just after noon, the scheduled launch time; but upon the request of the other builder, whose boat wasn’t ready for the water, the launch was pushed back to 3:00 pm. As a consequence, we lost some of our spectators, but we still had a crowd when we carried our kit boats down to the dinghy dock for launch. I was apprehensive but extremely proud of our boats and building teams. I needn’t have worried. The launches were flawless. Dean splashed first and was soon out of sight somewhere across the Mystic River. Carol, a Mystic Seaport member, took a turn out around the shuttle, then showed her docking skills as she maneuvered back into the dock and took me aboard as crew for a tour of the waterfront. It was a splendid highlight for me in the evolution of the Z-PDR, and both new owners were thrilled with their Z-Ducks.


The family boatbuilding site—our workshop for nearly three days. Carol and one of her friends are in the foreground; Dean and his wife Susan are in the background. My poster and sample sails and sail kit are on the right.

Dean and Susan plug screw holes with bamboo skewers dipped in PL Premium

Carol and her friend Arlene sand foils in preparation for the first coat of epoxy.

Kit #2 is epoxied and ready for the foam insert and decking. Time for lunch!

Nate helps Carol rig her sail.

Our launch T’s: “Puddle Ducks Can Be Deceptive”

The Z-Ducks wait patiently for security to open the gate. The guards  never did come, so the boats were hoisted over to waiting hands.


Dean rounds the shuttle and tacks off across the river

Carol launches and heads out in a light breeze.

Another successful launch!


What’s next for the Z-PDR? Well, testing her arsenal of sails and foils for one thing. Then we’ll see what the future holds.


60 sq. ft. racing weight leg o’ mutton on 17’ 6” mast.

85 sq. ft. leg o mutton with window. Mast extended to 20’ 4”

100 sq. ft. balanced lug sail. Mast reduced to 12’.




PolySail International

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This page updated on 7/13/2010