There is not enough volume for manufacturers to invest in a new mold ( ~20-30K USD ). As to the recommended boats - note that if someone is specifying paddler weight from 100lb to 220lb, they are involved in BS marketing. Also note that expedition class boats are meant to be paddled loaded.
Your options -
used composite boat, I would add Nigel Foster Rumour to the mix. Betsy Bay Idun is a niche boat, worth thinking about. Nigel Dennis Pilgrim, Valley Avocet LV might fit the bill, but I don't know anyone if the sub 100lb group paddling one. My friends, she is ~100lb x 5ft, picked up a used Rumour from here on P.net for 650USD, so deals can be had.
build your own - typical choices are strip built, stitch and glue, skin on frame. There are plans available for purchase, you can come up with your own designs. If I were interested in getting a boat that actually fits me, I would contact someone like Nick Schade and ask him to scale one of his designs down. Also, take a look at this http://www.rollordrown.com/kayak/index.html - there are free plans, Duane would, probably, be happy to work with you. Skin on frame construction allows infinite custom designs, there are workshops that teach people how to build them, Brian Shultz of http://www.capefalconkayak.com/ is on the West Coast.
URCHIN Portable Anchor
Recreational Kayak Paddle
|Table of Contents|