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c o n s t r u c t i o n t e c h n i q u e s Ryujin and Wasabi (12m racer) Infusion process LOA 12.0 m Beam 3.737 m Draft 3.0 m Displ 4400 kg
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This Sayer 12-MO is a newly developed 12m class racer designed specifically to compete in the 2007 Melbourne/Osaka yacht race.
Based on inputs from Sayernara, Team FGI and Belle, these yachts have been commissioned for an extensive sailing program culminating in the Osaka race of 2007.
Building materials from Fiberglass International have been used exclusively for the projects, with FGI's engineering arm, EMP Composites, having full involvement to ensure that the latest technologies are employed.. The owners' briefs were to primarily design and build a yacht capable of successfully handling the unpredictable race conditions of the Melbourne to Osaka Double Handed Yacht Race. Even though the two yachts are out of the same mould and have been designed primarily for the same yacht race, they will not be identical. Ryujin-FGI is a carbon / kevlar composite construction with tiller steering. Wasabi is a full carbon fibre yacht with twin wheels. Both yachts have have been designed and built using the most up-to-date construction technologies employing resin infusion methods at the SYS temperature controlled factory.Both 12 metre yachts have been designed to carry water ballast, have a draft of 3 metres and a displacement of 4 tonne. Boasting twin wheels with her signature colour of wasabi green, this latest yacht is a beautiful fast lady and will attract attention wherever she is sailed. Both yachts have been constructed by Sayer Yachting Services and have used Fiber Glass International's products in the infusion laminating process. Material design came from their engineering arm EMP Composites run by the very experienced Australian Designer/Engineer and sailor, David Lyons. The Diab team who are the masters in this technology assisted with the core materials and process. Below, is a step-by-step guide to the construction process. |
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Deck mould under construction Computer cut frames from the design files to ensure very accurate building platform Note: Tilt slab factory construction for climate control |
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| Deck mould set up |
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| Sheathed and faired ready for painting |
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Undercoated deck mould ready for final sand and paint |
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Hull mould from computer generated stations done in female form to save weight compared to lapped glass and filler required on male plugs |
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Hull mould half - faired ready for filling and painting |
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Finished hull section ready for lay-up showing vacuum flanges. The final infusion and baking process will be carried out in the workshop's climate controlled environment which includes air conditioning, paint booth and oven booth aimed at yachts under 14m LOA. A removable panel oven wall facilitates the movements of the hull into the work chamber |
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Deck mould painted ready for final wet and dry and polish |
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Even the owner cannot escape the tedious mould preparation
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Polished surfaces readied for final wax. The foam will be pre-fitted prior to wax finish to save surface |
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Computer cut bulb halves ready for casting |
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Large vacuum table to facilitate the infusion of all interior components to ensure true flat surfaces and accurate resin/fibre ratio in the building of bulkheads and the minimal furniture that will be used |
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Rudder shells from 3D computer cutting to ensure precise design transformation. Locating pins secure perfect halves for bonding |
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| Centre board case and keel shells made with accurate 3d CAD construction |
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| Heat forming and pre fitting special DIAB infusion core |
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| Vacuum panels made on table for resin control through infusion |
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| Panel fully infused with clean environment |
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| Main bulkhead half showing carbon strapping |
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| Deck pre laid out with foam and cut outs for high density core pads included |
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| Carbon and internal skins laid down |
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Clean work with no resin application till final infusion |
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| Extra reinforcing pads on all high load deck fittings |
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After the last layers of glass, the whole surface is covered with a vacuum bag and plumbing added to facilitate the infusion process. Care must be taken to ensure a total vacuum. This can be dealt with in a slow methodical process as there is no resin near the job and quality is assured |
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Resin take up lines in strategic points, are placed around the job ready for the infusion |
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| Infusion lines |
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| Infusion lines |
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Precise measuring of catalyst ratios are required and we are ready to go. The deck in this case is vinylester resin but the remainder of the yacht is built with epoxy. Your FGI rep will advise the best solution for your yacht |
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Infusion working from a centre feed to the outside |
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| Initial progress |
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| A dedicated hand to every entry point |
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| A check can be made to ensure the process is infusing correctly without getting your feet wet |
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The completed job with no mess and no fuss. The wet-out can be easily viewed as the process evolves. The discoloration is due to different peel ply brands. |
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Infusion technology has it's advantages Let"s see you wet out a 40ft racing yacht deck in 50 minutes from start to finish with no sticky fingers.
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| Half hull Foam heated and formed to hull shape |
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| Hull half with layers of carbon fibre fabric, vacuum bagged and being infused with resin |
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| Infusion job almost complete |
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| Hull half being lined up with deck and getting ready for bulkheads |
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| Hull halves joined |
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| Fitting the deck to the hull |
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| Paint stage "Wasabi green" paint specially mixed for the client |
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| Attaching deck hardware Note; Carbon fibre tubes for bowsprit |
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| Keel fabrication |
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| Preparing to fit the keel to the hull |
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| Lining up the keel bolts |
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| Launch Day Wasabi's first dip |
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| Floating on her lines Note : Carbon fibre mast and boom |
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| Tied up at the dock and boasting twin wheels |  |