Father-and-son team reinvents the kayak

Gliding past the Derby Wharf Lighthouse in the evening, it is quickly obvious where kayakers find their passion for the sport. The water is silent, other than the dripping of water from the paddle onto the deck as the oar rotates, easily pushing the craft ahead. The sun dips toward the horizon, and a soft golden light has settled on the boats scattered in the harbor. Only a few feet from shore, and the world seems at peace.

Ted Warren and his son Zac Warren paddle together, at ease in their crafts. They should be at ease — Ted designed the Littlewing kayaks they are taking out for an evening spin. One red, one blue and one yellow, the three elegant and luminous crafts cut effortlessly through the waves from a passing yacht.

Both graduates of MIT, the father and son team run Warren Light Craft out of a showroom and factory at the back of Derby Street. A small sign leads curious passers-by from the main street down past an alley of shops to the Warren’s space at the end of the building.

Their showroom is as close as you can get to the short inlet that runs beneath the Congress Street Bridge, convenient for excursions with potential customers or a solo paddle after work.

“I think you’re born with salt water in your veins. Or you’re not,” Ted Warren laughs, eyes crinkling behind tinted glasses. He describes how he’s introduced some people to kayaking for the first time, and they’re hooked for life. They start paddling two or more times a week, for hours at a time.

Most beginners probably start out with a traditional Greenland style kayak, the design that was introduced by the artic country’s indigenous people, Ted explains. Made of plastic or composite fiberglass, most commercially-produced kayaks on the market are Greenland style and are often too heavy to carry for long stretches, and are slow to maneuver.

“I’d been thinking about the design of the Littlewing for a long time,” Ted says, as he dives into the history of his achievement. “I wanted to make improvements to the traditional design: Weight, stability, speed. Those are the three important characteristics. I started by drawing concepts on the computer, and the shape evolved with the different drawings.”

The Warrens made two early prototypes, the second of which is “pretty close” to the final design, which has won industry awards. They offered that second prototype to a few expert kayakers to try out, and incorporated all of the feedback they received into the final design.

Their three models, all named Littlewing, feature the same curvaceous shape. The primary difference between them is the size, and therefore weight. The Littlewing 14 is just over 13 feet long and only 26 pounds, and the Littlewing 18 — designed largely for expedition kayaking — is more than 18 feet long and still just 36 pounds. The Littlewing 16 falls in the middle.

“The 14 is good for most people. There’s a very high fun rating on the 14,” Ted says with a grin. “All of these boats are half the weight of the competition,” he continues energetically. “Our target is the mainstream paddler. These boats feel secure for the average paddler; they have the stability for beginners to feel comfortable.”

Ted designed all three models. Before starting Warren Light Craft, he made his living designing and building performance sailboats. To create a unique kayak, Ted used the design and construction techniques he had learned and developed on sailboats, and applied them to a new type of kayak design.

The Littlewing models get their name from the widened shape at the fore and aft of the boat. Ted’s hourglass design is narrowest in the center for good ergonomics, and equal in width at each end for stability. The rear wing can be pushed into the water for a quick wet re-entry, which is typically a challenging feat for even the most advanced paddlers in a traditional kayak.

Zac demonstrates how important speed is in getting back in the kayak after a spill, as he tips himself into the chilly, 57-degree harbor.

“They say it’s the 50-50-50 rule,” his father explains, as Zac shivers back in his boat. “At 50 degrees, you have a 50 percent chance of swimming 50 yards.”

“Some people flip, and then figure they might as well swim to shore rather that try to get back in,” Zac explains. “But in these water temperatures, you’re much better off if you can get back in your boat.”

The Massachusetts State House is currently considering a bill that would require all students taking kayak instruction to first receive training on how to exit their kayak when it flips over. While instructors oppose the bill because it may undermine beginners’ confidence during lessons, or interfere with the instructor’s judgment when the water is too cold for wet training, Ted Warren is one of many in favor of the idea.

“It’s important,” he says about the wet exit training. “There’s a mental block against getting wet, but once you do it, it’s ‘let’s do that again!’”

Father and son both construct the kayaks together in their factory, located behind the Warren Light Craft showroom. Each boat is custom-made and averages a two-week process from start to finish. Crafted in two separate pieces, the deck and the hull are molded from a stiff foam core that is thermoformed into shape, fitted between two layers of composite carbon fiber, and sealed together with epoxy. The result is a light, durable, waterproof frame that won’t crack. While it may dent under impact, it can be easily filled and repaired, similar to a dent on a car body.

Because these kayaks are custom-made, there are limitless options for paint and exterior graphics. “Someone from North Carolina tried a boat out recently,” Zac says, pointing to a gleaming silver craft in the showroom. “He ordered one, and we painted it to match his Mercedes Benz.”

Orders have come in from all over the world, Zac adds. So far, the furthest has been Norway. Tourists visiting from across the East Coast and Canada drop into the shop, as well as many customers from Salem. Business is good, and the Warrens have sold every kayak that they’ve made in their two and a half years in business.

“What’s great about being located in Salem is the rich maritime history here,” Ted says, sweeping his arms around, taking in the historic surroundings. “I don’t know of much ship building here now, so it seems fitting that we’re here.”

While Zac returns the sleek boats to their places in the showroom, and cool drops of saltwater drip and puddle on the cement floor, Ted watches him with pride. His family is doing what they love, and they’re able to share their passion and experience with others. Other than a long paddle on a quiet stretch of sea, what more could one ask for?