We visit the world headquarters of Northstar Canoe in beautiful Princeton, Minnesota, where Michael Carney picks up two brand-new canoes that will travel everywhere from South Florida to the Boundary Waters and beyond.

Joining us is Bear Paulsen — PR man, historian, canoe enthusiast, and educator — who walks us through the entire canoe manufacturing process. From raw composite fabrics to the finished boat, we get an inside look at how high-performance composite canoes are built by hand.

This is a real working tour of the factory, so you'll hear the sounds of everyday canoe building while we explore each step of the process.

In this video you'll see:
• How canoe molds are designed for long-term consistency
• Kevlar and composite fabrics being laid into the mold
• The vinyl ester resin process and vacuum bagging
• Strategic reinforcement for strength without extra weight
• Foam cores and structural ribs
• Hand-built wood components including seats and yokes
• Carbon fiber trim and ultralight canoe construction
• The finishing steps that turn raw materials into a finished canoe

Every canoe built at Northstar is handcrafted, meaning each one has its own unique character—just like the wood grain in a fine piece of furniture.
By the end of the tour, we see the finished canoe come out of the mold and get ready for its first adventures on the water.
If you love canoeing, craftsmanship, outdoor gear, or the Boundary Waters, this behind-the-scenes tour is a fascinating look at how some of the best composite canoes in the world are made.

Learn more about Northstar Canoe:
https://northstarcanoes.com

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