I have yet to touch the water with my first kayak, Current Design Titan (fiberglass). I hear why so big? Well, I'm 6'3", 244 Lbs, 34 inch inseam, and the two critical factors are shoe size 13 and hips of 45 inches.

I need to add padding in the cockpit to fill the void from the outside of the knee to hull.

Could anyone direct me in the proper application?

I'm no expert in this matter, but Northwest River Supply (NRS) has all kinds of stuff for padding out and custom-fitting your cockpit to your dimensions. http://www.nrsweb.com

I am about the same height and usually weigh in at 210. The trick to getting your legs comfortable is two fold. First you knee and ankle should be at a "neutral" angle. Visualize the angle they set broken legs/ankles at. The contact from the knee to deck helps with bracing, but don't wedge yourself in or it will get uncomfortable after a few hours.

The second problem you will discover is that the seat base was design for people who are shorter. The way to overcome this is to place piece of closed cell foam directly infront of the seat. This will support your thighs and avoid placing a downward force on your knees. Having had a knee surgury or three---- and the #@&! left knee is kicking up again. Any unusual stress hurts after a few hours.

A great source of thick closed cell foam is firms that makes seat cushions for sailboats.

Bill

my heart bleeds for you little guy.I'm 6'10"250 size 15 shoes.I don't have a kayak yet but I'm seiously thinking of a greenland style skin on frame.

Vegasrandall, have you considered a tandem hull with a custom solo deck? Just kidding, but I would suggest that you might indeed need a custom built craft.