The Stages of our Build Process a Step by Step Guide to Construction.
Stage One : Lamination
The beginning of the construction of your boat starts with the Lamination Process. Lamination is a term used for hand laying multiple layers of fiberglass material in a mold. Our boats are 100% composite, made of fiberglass, resin and high-density foam transoms and foam core. We laminate thru an open molding process. Your hull, deck, hatches and console are built from the outside-in. This means spray your color (gelcoat) into the mold first and then hand-lay the fiberglass on top of gelcoat.
First the molds are waxed and prepped for a smooth surface. Your selected color is then sprayed in the mold to our desired thickness. This gelcoat layer is left to set up before fiberglass is laid into the mold.
A skin-coat (very thin layer of fiberglass) is then applied to the top of the gelcoat layer as a water proofing barrier and also a bonding surface to laminate on. The skin coat is then left to cure. Once cured we grind the rough edges off and create a scratched surface to begin lamination on.
The structural lamination process begins. We use high quality biaxial structural glasses and we hand lay each layer one at a time. In some areas on the hull, decks and consoles we install core for strength and mounting ability. This core is a high-density foam material that won’t break down or rot if it gets wet. Core that’s embedded in fiberglass also helps to hold screws in areas where we mount rod holders, electronics etc. Once the core is installed we add additional layers of laminate on top of the core until we reach the desired thickness and strength.
After the lamination is completed we install the transom. The transom is made of high-density foam board. We then drill a series of 1/4” holes and apply resin and glass to the transom between the hull glass and the new transom material. We then clamp the transom material tight to the hull and the glass and resin pours thru the series of holes that lock it in. We then glass over the top of the transom to finish it off. This process is a “lifetime” lasting method that will not break down or rot.
After the transom is completed and cured we then install the stringers by setting them in place and then bonding them the hull. Once the glass on the stringers cures we then drill 2” holes along the tops of the stinger grids and poor them full with structural foam that adds strength and floatation. We then add more foam to the empty voids, which adds additional floatation and quiets the hull at speed.
We then pull the hull from the mold and prepare it to begin the rigging process.
Stage Two : Building
Building the deck (liner), console and small parts. Small parts consist of the hatches, storage liners, toe kicks, bait wells etc. These items are typically built just after the hull is complete and in the rigging process. On some occasions we build them first if our molds are available and the process is quicker by doing so.
This process works the same way as the hull construction. Gelcoat first then hand laminated layers of structural glass. Core is applied where necessary for strength and mounting areas.
Stage Three : The Rigging Process
The rigging process begins, and is the most time consuming phase of the build process. Rigging is when we install all of the wiring, plumbing, fuel systems, electronics, t-tops, towers and other specified options before delivery. During this process some parts are fabricated for you and some are ordered in based on what you’ve selected. At this time there’s still opportunity to change items and options as long as they aren’t already installed or custom fabricated. Below are the steps taken during the rigging process.
Rigging the hull and deck. This is the first step in rigging process. The hulls and decks are rigged separately before bonded together. The hull is outfitted with a fuel tank, plumbing and thru hulls, pumps, wire harness and basic wire connections are made to items attached to the hull. Jack plates are also installed before the deck goes on. The decks are outfitted with rod holders, cleats, hatches, fuel and water fills and other selected items that get mounted on the deck.
Pre decking. In this phase the console is mounted to the top or tower you selected and then lifted into the deck. The top is then thru bolted with large 1/4” aluminum backing plates before the deck is installed to the hull. This ensures a strong safe bond especially for towers.
Once the Hull and Deck are pre-rigged and top or tower is installed then the two parts are ready to be bonded together. We use a combination of a chemical and mechanical bonding process. We use the highest quality bonding material to fuse the deck to the stringers and the upper edge of the hull where the rub rail is installed. The mechanical bond takes place by installing the rub rail. These additional screws add rigidity to the chemical bond. The deck and hulls are designed to bond permanently.
The final stage of the rigging process begins after the hull and deck are fused. We then begin to make all final wire connections, plumbing connections, install electronics, and other specified options. We then install the rub rail and last the engine and upholstery. Most modern engines need to be programmed to work with the new style electronic fly-by wire controls. Other electronics, radars, security and autopilots are also set up and programmed.
Stage Four : Water Testing
Pre-delivery and water testing. When all of the final rigging is competed we test all options and electronics installed on your boat. We add oil and prime the fuel system and engine. We then check fluids in all of the pumps and install your batteries. After all items are tested at the factory we run you engine on a fresh water hose for 20 minutes and run engine diagnostics. We check the shifting positions, throttle and steering. Once everything is up to spec we take your boat to the water and test everything installed for a second time in a real-time use situation. We then run the boat at various speeds for no less than 1 hour to begin the break-in on the engine. While doing this we set up all electronics and test radios as well.
After we dial everything in we wash the boat and prepare to deliver your new custom fishing machine to you!