Technology & Material

"The Klepper is the Mercedes Benz of folding boats."
Randel Washburne, The Coastal Kayaker

Aerius Cutaway

Clickable Image Map


Descriptions of Features and Materials

Mountain Ash and Baltic Birch Frame
The wood is air dried over three years and every frame member is protected through three dip-painted coats of premium marine varnish. The rugged I- and T- beam construction withstands bending, twisting, and compression. This ensures safe and successful transit through the most adverse environments. The Aerius is carefully engineered for demanding military and expedition use in rough open seas, white-water navigation and sport sailing. The natural wood frame enables quick and easy repair and requires a minimum amount of maintenance to ensure a lifetime of reliable service. For further details, click on 'Performance and Benefits'.Back to Kayak

Orthopedic Seats
Contour-Molded seats and backrest provide a superior body-to-boat contact. These are arranged in a spacious cockpit for the best trim and efficiency. The seats may be supplemented with an adjustable lower lumbar support system to provide hours of comfortable and stress-free paddling.Back to Kayak

Cotton / Hemp Deck
All decks are made from selected Egyptian long-staple, self-sealing cotton/hemp. This allows the deck to "breathe". The natural air circulation eliminates excessive condensation and provides natural waterproof insulation. For further details, click on 'Performance and Benefits'.Back to Kayak

Hypalon Hull
The boat hull is made of Hypalon (natural rubber) which is bonded to an industrial-strength Trevira polyester core. The synthetic rubber offers hull life expectancies of 25-35 years. The Trevira polyester core provides the necessary flexibility for the skin and makes the hull nearly indestructible.Back to Kayak

Slide'n Snap Fittings
The corrosion-resistant Dural alloy slide'n snap frame fittings make assembly effortless in minutes, provide frame flex under the harshest conditions, and are 100% mud and sand-proof. For further details, click on 'Slide 'n Snap Assembly'.Back to Kayak

Upwind Sailing
Mast foot, mast support bracket, stayfittings and rudder bracket are standard on all models for the set up of several upwind and downwind sail rigs which range from 14 to 55 square feet of surface area. For further details, click on 'Upwind Sailing'.Back to Kayak

Hypalon/Trevira Keelstrips
The keel is reinforced with additional Hypalon/Trevira layers which provide superior protection against coral, rock, and man-made hazards.Back to Kayak

Contour-Molded Rubber Caps
Bow and stern are reinforced with thick contour-molded rubber caps for maximum protection during landings and take-offs.Back to Kayak

Tow and Lift Fittings
Heavy-duty Dural alloy fittings on the bow and stern of the boat deck allow for 600 pound tow and lift operations.Back to Kayak

Integrated Air Sponsons
Two (four) internally-mounted, full length air sponsons contain between 65-150 liters of air and assure maximum stability, safety and hull protection. The air sponsons allow for effortless assembly of the boat frame inside the boat skin, maximum protection against capsizing and easy re-entry into a stable very buoyant boat when swamped. For further details, click on 'Safety Engineering'.Back to Kayak

Bow-to-Stern Warranty
This covers all defects in materials and workmanship. All models of the Klepper Aerius series are hand-crafted in Germany with the finest materials and master workmanship. Proved through decades of use from the arctic to the tropics, Klepper Kayaks are consistently selected by expedition outfitters, military special forces and professional sportsmen.Back to Kayak

Conversions to: Solo-Paddling, Motoring, Sport Sailing
Conversion to solo paddling is an option for all two seater Aerius models. Conversion to sport sailing and motoring is optional for all Aerius models.Back to Kayak

The Aerius Materials

  • Air-Dried Aged Mountain Ash

  • Egyptian Long-Staple Cotton Hemp

  • Trevira-Polyester Core Hypalon

Air-Dried Aged Mountain Ash

The boat frame is made of mountain ash. Ash wood is air-dried and aged for at least three years in order for it to develop its famous resilience. Air-dried mountain ash is used today in fine sporting equipment, from skies and golf clubs to bows and hockey sticks. Wood as a boat frame material offers several major advantages: it is one of the strongest and most functional materials available, is literally maintenance free, allows for easy field repairs, and has a specific gravity of less than 1.

Performance Benefit No. 1:

Strength & Flexibility

Here is How it Works:
Nature can be copied but not duplicated, as the structure of a wheat stalk shows in relation to the weight it carries. To build a boat frame as strong and resilient as an Aerius frame out of materials other than mountain ash would result in a frame more heavy or expensive.


Performance Benefit No. 2:


Here is How it Works:
Klepper employs a 3 step dip painting process to seal all wooden frame parts for up to 50 years against water penetration. This unique protection makes Klepper frames last longer and requires less maintenance than any other boat frames.

Performance Benefit No. 3:

Additional Flotation

Here is How it Works:
Should you ever capsize wouldn't you want to have all the extra flotation you could get ?

Performance Benefit No. 4:


Here is How it Works:
Looking at and touching the wooden boat frame is beautiful and enjoyable. In fact, some people actually display their Aerius frame in their living room like a piece of art work when not paddling.

Egyptian Long-Staple Cotton Hemp

The boat deck is made of cotton hemp. A proprietary weave of Egyptian cotton and hemp assures continuous air circulation and a healthy interior boat climate. In addition, the natural material provides a perfect fit of the boat skin and seals the deck watertight without the use of chemicals or artificial sealers

Performance Benefit No. 1:

Cool Interior

Here is How it Works:
The breathable Cotton Hemp deck facilitates natural ventilation and evaporation of water. From the Arctic to the Tropics the boat interior is never colder (arctic) or hotter (tropics) than the outside air temperature.

Performance Benefit No. 2:


Here is How it Works:
The cotton hemp fibers swell in contact with water, thus naturally waterproofing the boat deck while still allowing air ventilation. This eliminates the use and/or periodic reapplication of chemical sealers.

Trevira-Polyester Core Hypalon

The boat hull is made of a heavy-duty Trevira-Polyester weave core (similar to a car safety belt) that is coated on both sides with a thick coat of proprietary synthetic rubber (Hypalon). This manufacturing process allows the hull to maintain it's shape and pliability from - 25° C to + 65° C. The trevira-polyester core increases significantly the puncture resistance of the hull.

Performance Benefit No. 1:

Puncture Resistance

Here is How it Works:
The hull is built like a conveyor belt. Upon impact it flexes and absorbs the energy, thus avoiding damage.

Performance Benefit No. 2:

Cold Water Insulation

Here is How it Works:
The multi-layer hull provides the very best cold water insulation and comfortable boat interior.

Performance Benefit No. 3:

Easy Repair

Here is How it Works:
Hypalon is a synthetic rubber. In the case of an accident a hull puncture can simply and quickly be repaired, similar to a bicycle or car tire inner tube, even in the field and under the most adverse conditions.

Performance Benefit No. 4:

Shape Retention

Here is How it Works:
Your Klepper skin assembles easily and fits perfectly in all climate zones and temperatures, even after 30 years of service.

Our Commitment to Excellence

Wherever possible Klepper has followed important trends and developments in boat building technology. Military forces from around the world were some of our most demanding customers, and have provided us with many valuable suggestions and design changes over the years.
National CPR Association