We stared off with 16 foot long pieces of plywood called blanks. Then you want to find your measurements to the side of the kayak, or use a pattern to trace them on the blanks. Then cut it out, but don't cut on the line, cut a little above it on the waste side. After that, grab a plane and shave it down almost to the line and finally use a Surform, which will give it a nice finished look. The picture on the right is the finished side panel we used. The picture on the left is a Edit[handsome] man in a kayak (me)=) !
