Our bulking method is like no other. We armor our boats for all conditions and this is how.
We pride ourselves in our lamination process. It’s the foundation of what will end up in the water. Hitting seas, turning corners, and rough environments are what we prepare for during our bulking part of boatbuilding. Think of this section of the process as the armor. The part where we suit up all of our boats to prepare for all conditions. A knight in shining armor. But, this one is made of tougher materials. Sorry, Sir Galahad. Most boatbuilders use traditional open-molded fiberglass laminate. They lay it in the hull and spray the resin to ensure that it’s fully saturated. Then, they roll it out. Other boatbuilders will then repeat this over and again with each layer. Not us. We meticulously hand lay with dry and heavy fiberglass mats. This ensures better control and placement of each engineered fiberglass mat. Not all fiberglass mats are created equal. All have a specific engineered purpose in our hulls and decks. For instance, this one is a 108 oz. stitched and woven mat.
It does all the heavy lifting in the Infusion process. These mats are so thick, that without infusion, it would be difficult to get the resin to absorb with traditional boat building methods that you might see in other boatbuilders. One of our bragging rights is that we use all composite materials. Not a single touch of wood. No wood means no rot. These are just a few examples of the composite materials that we use for our backing, coring and transom.
Then, we come in with the stringer system. It’s a high-density closed-cell foam. Then, it’s all CNC-routed for that specific hull to match the deadrise angle. After that, we put the bulkheads inside the hull, which ties all the stringers together and to the hull side. Think of it like going in the attic of your home and seeing the crossbars that hold up the roof. All different angles and sizes to make it solid for protection.
We then encapsulate with another set of laminate layers. Producing boats this way allows for it to become a single-piece structure (Single-Piece Infusion, SPI). We craft our boats this way because it ends up being the strongest boat on the water. In fact, it is two-and-half times stronger than the traditional open-molded boats. This allows for better control over the entire manufacturing process. Open molded boats are 40% glass and 60% resin. We achieve a perfect glass-to-resin ratio of 63.5% and 36.5%. On our end, resin is just the glue that helps hold it together, not for structural purposes. With these results, there are no secondary bonding issues and a variance in weight that’s less than 5%. In turn, better weight control and more fiberglass per square foot. Of course, that’s a lot of numbers. But know this, it means a rock-solid boat that is light on the water and bares more consistent parts across the entire build.
This is the best-known manufacturing method to build a boat. And, that’s why we do it.