Wavewalk S4 mold completed

The S4 mold got coated with Teflon, and our mold makers are done with its final inspection.
It’s on the way to its new home at the production facility where our kayaks and boats are made.
Developing and producing such a large size cast aluminum tooling is a complicated and lengthy process, and it was carried out pretty much on schedule.
We are planning to produce the first S4 units next week.


The top part of the S4 mold. The golden-brown glossy material is the Teflon coat.


The purpose of coating the inside of a mold with Teflon is to prevent the Polyethylene from sticking to the mold after it’s cooled down.
If the Polyethylene sticks to the mold, the production team can have a hard time taking the molded boat out.


The mold’s top part viewed from another angle.


Close up of the bottom part of the Wavewalk S4 mold


The bottom part of the tooling suspended from a crane


Rear view of the bottom part (upside down) – The bottom half of the rear carry handles can be seen


The Wavewalk S4 cast aluminum tooling waiting to be picked up

12 thoughts on “Wavewalk S4 mold completed”

  1. You mean the S4 in the “Mud Brown” color? ๐Ÿ˜€
    BTW, the commercial name of the brown color that our molders found is “Pacific Brown”, but I like “Mud Brown” better…

  2. You should name it Duck Hunter Brown! I am very excited to see what can be done in that kayak with the extra weight capacity as well. There is a bow hunt for elk out here on a slow coastal river. The hunting area is only accessible by paddle craft and you have to be able to take your elk out by kayak as well. The S4 might just be the ticket that puts me in the game. ๐Ÿ™‚

  3. Then we’ll name this color “Duck & Elk Hunter Brown”! ๐Ÿ˜€

  4. I have to be honest – I like the golden brown Teflon coat color the best!!

  5. ๐Ÿ˜€ ๐Ÿ˜€

  6. That Duck & Elk Hunter Brown might be just the ticket where the water is muddy and chill fills the air. I ordered the white S4 because our Caribbean water is clear and the light colored saddle is cool to the touch here in the tropics.

    Easily, the S4 will accommodate two bikini clad ladies with my experienced hand steering the motor at the stern. Dark saddle color in hot sun = fried bare inside thighs.

    All depends on what you are aiming for…

    Larry J.

  7. Our molders received the S4 tooling (rotational mold), and we’ll try to start producing and shipping S4 boats this week.


  8. Pyt Rotary says:

    Looks great.
    Great achievement.

  9. What’s particularly amazing to me is how they manage to cast with high precision an aluminum wall that’s thin yet uniform ๐Ÿ˜ฎ

  10. And here are some photos that our molders shot at the S4’s new home:

    Wavewalk S4 tooling


    S4 mold


    S4 kayak rotational mold

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