Hull Construction: The hull is what they refer to as a “one off”, not molded hull. It was layed up over
frames and battens in an inverted position. A fine mesh was stretched and fastened to the battens to enable the initial lay-
up to begin. The inside layers were constructed first, then end-grain 3/4” Balsa core was applied over this layer, followed
by the build up of the outer layer. All layups were hand applied. The hull was then filled, faired and sanded to bring it to
molded quality. The above water area was then painted with 2 part poly-urethane primer and paint. The under water area
received an epoxy barrier coat . The nominal thickness of the hull is around 1 3/4 “.
When installing thru-hull fittings the inside layer of fiberglass and the core were removed. Then the area was re-laminated
with a solid resin and fiberglass buildup to ensure no ingress of water between the layers of the hulls.
The ballast of concrete and lead was pored into the hull then covered over with another fiberglass buildup to encapsulate
it.
Tank Construction: The tanks, both water and fuel are built into the hull after hull construction was
complete. The fuel tanks are built in place, and the ends and baffles were made from pre-cast 5/16 fiberglass sheets cut to
the hull shape and glassed into position in the hull, after another 5/16th skin was formed in place. The lids are set into
wet fiberglass and mechanically fastened with SS screws, then an addition 1/4” of fiberglass was layed up to covered the
joints. This made the tank thickness at the joints 3/4” of solid fiberglass. Two inch diameter fiberglass vent and fill pipes
were glassed into the lids. The tanks are very heavy construction to avoid any possibility of failure or leakage. Sumps were
made in each tank at the lowest point. The fuel is drawn from there, to ensure any contamination would be immediately
removed from the tank, via the filter system.
Deck Construction: The deck is constructed with 3/4” marine grade plywood that is long spiced at the
joints and glued together. It is supported on 2 x 2.5” glue laminated fir beams on 16” centers and mechanically fastened to
the plywood. There is a layup of a full 1/4” of fiberglass on the plywood deck. There has been no de-lamination or leaks.
Pilot House Construction: The pilot house is constructed of marine grade plywood, then
fiberglassed, faired and painted. The pilot house was bolted to the decks , then fiberglassed to the decks. The windows in
the pilothouse are all tinted tempered glass. The front windows are 3/8”, while the sides and aft windows are 1/4”. There is
a self draining step-well behind the pilothouse to allow for a full sized entry door. The door is fiberglass over plywood
construction.
Stern Extension Construction: The stern extension was built, then later attached to the boat.
it is built of pre-cast and molded fiberglass and then attached to the transom and hull. The attachments are carefully layed
up inside and out to ensure positive and complete bonding to the origin material. The integrity of the original transom was
not compromised.
