Hull and mould fabrication                             

The hull station frames were cut by a CAD-CAM router machine loaded directly from the Maxsurf software to achieve the most accurate hull mould possible without 5-axis tooling.  

Longitudinal stringers were formed over the stations.  Flexible ply was then laid across  the pine strips and stapled into position. A layer of fgi fibre glass was fixed to the ply, prior to fairing, sanding and painting.  

HULL - Longitudinal stringers over the frame stations

Keel and mast compression girder framework

The keel and mast compression girder frame work has been cut into the hull mould to ensure a neat and professional finish internally.

Keel and mast compression girder framework cut into the hull mould

Deck mould fabrication

In contrast to the hull, the deck will be fabricated from a female mould.  Similarly to the hull, the station frames for the deck mould have been cut to form the designed shape. Although accurate, this mould will be left void of contours and impressions so that future yachts may be tailor made for the customers' own thoughts on deck layout.

Deck mould

The process begins ensuring an accurate forming of the bow section to ensure strong chainplate adhesion in a later process

Placing carbon fibre on the bow section

Once the initial primary inner laminate has cured, extra uni-directional fabrics and stitched fabrics are added to reinforce the keel-mast area for greater strength. Large de-bulking of excess resin is required in these difficult areas by vacuum bagging

Re-inforcing the keel-mast area

Klegecell specialises in different types and grades of foam for the required areas on the modern yacht. Consult your rep for the best results. "Team fgi" has her keel and slamming areas portioned in a higher density core for superior 'core-shear' properties.

Keel and slamming areas strengthened

The outer skin has been hand laid in position and the whole laminate is vacuum bagged to the foam for a superior bond and weight to resin ratio for the final skin. The new Fiberglass International resins are ideal to match the temperature with the open time for ease of lay-up without getting caught out and rushing the job. The wet lay-up was applied in the cooling air conditioned enclosure and then the temperature was then elevated for the cure.

Bleeder cloth

Checking the bag for any air holes to ensure a good vacuum.Note the bleeder cloth which allows drainage of excess resin to be removed and also to allow a thorough bleed of air which can travel from remote areas to the suction point.

Hull is covered in bleeder fabric to remove excess resin during vacuum bagging

Nothing can compare with the accuracy of the long torture board to give a truly fair curve on the hull surfaces. Hired hands usually run for the hills when this apparatus hits the shop floor as it entails hard work for a few days to bring the hull to its final coat.

Longboard sanding

After some gentle coaxing around the edges and a few blow holes in the bottom of the hull, the hull is released from the mold.

Raising the completed hull off the mold

The hull is wheeled outside to allow room to turn the hull over

A single point lift is all that is needed for the hull shell with keelson and floor girders to be turned over

Turning over

The completed turn and she is ready to be wheeled back into her controlled tent environment for the fitting of all the ready made furniture and bulkheads from the vacuum table

Nestled in the cradle to be wheeled back inside.

The internals are fixed to the hull shell

All bulkheads and girders are glass and carbon taped into the hull to make a strong light weight structure

From bow to stern showing D/berth 

Midships looking aft showing longitudinal bunk structure, centre cockpit web and engine installation under cockpit.

Engine and fuel tank

Central shot showing mid bunk girder support to break bunks into two x  2 metre bunks each side 

Middle forward

The bottom is fully finished with keel and rudder fitted, prior to heading to the launch pad

Launch day

The last feel of dry land before the lowering into the water

Final approach

Team fgi was officially launched

8 February 2003