CONSTRUCTION MANUAL

Interceptor & Wildcat 

Information and pictures on the construction of our boats

 

It all begins with the removal of a completed hull from the mould. All the b/heads and scantlings are completed at this stage. The moulding flange has yet to be cut off.

 

 

 

 

 

Right is a photo of a nearly completed Interceptor hull moulding showing nearly all of  the frames in position, bulkheads fitted, longditudals and panel breakers. The next stage is fitting the deck structure.

 

 

 

 

 

 

 

 

 

Here is a Pilot boat hull which shows massive transverse framing at 400mm

 

 

 

 

 

 

 

 

Here you can see the deck beams (4"x2") fitted at 400mm centers, taking a measurement from the centre of the b/head and moving out 8" either side then 16" more and so forth spaces the deck beams, the b/head is then notched to receive the beams which are then glassed into the b/head.

 

Here the margin board are fitted half way over the out board beam and out to the hull side,  scribed around the frames to give a close fit. The margin boards are then completed and temporarily fitted right around the hull. This gives an accurate guide to mark out the deck shelf, which is cut in a triangular shape 4" x 1" out of foam and glued to the hull side 6mm below the margin board (this allows for the thickness of the fiberglass over the deck shelf)

 

 

 

 

The deck shelf is being fitted here and will be laminated with 2 layers 900gm2 CSM glass.

It is very important that the deck shelf is positioned with care or there may result in high or low spots in the deck.

 

 

 

 

 

 

 

 

 

 

 

The deck shelf has been laminated and the margin boards fitted ( the plywood is bedded on to silkaflex and screwed down every 6"). The next step is to laminate the top of the margin boards to the hull with two layers 900gm2 CSM extending at least 6" up the side of the hull and each layer staggered. (The first layer 6", the second 5")

 

 

 

 

 

 

 

Here you can see the support pillars in position ready to be glassed onto the frames, note they are always positioned on frames not on the shell.

 

 

 

 

 

 

 

 

 

This picture of a Wildcat deck under construction clearly shows the complexity of the deck beam structure.

 

 

 

 

 

 

 

 

 

The margin boards are now glassed and the internal surfaces of the hull are flow coated, grey here. The deck beams are also flow coated. Next the deck is built and fitted in the same way, cutting out for hatches where necessary and the completed deck is then sheathed with one layer of 900gm2csm.

Note if teak and holey cabin sole (internal only) is being fitted then the deck is not sheathed, as the teak and holey 6mm boarded is glued to the plywood.

 

 

 

 

 

Here the plywood deck is being laid, and next photo sheathed with 900gm2csm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Here the deck for the fore cabin is completed and has been sheathed. The next step is to fit the fore cabin b/heads. Here the sole also serves to reduce the span of the transverse frames.

 

 

 

 

 

 

 

 

Here you can see the superstructure after it was removed from the mould, turned over and the windows cut out, now being lifted.

 

 

And positioned on to the hull mould when it will first be bolted together, then the hull to deck join will be laminated together. This is Barrinthus being built.

 

 

 

 

 

 

 

 

 

 

With the cabin sole completed work begins on the first fit out of woodwork involving forming the seating  (shown right) which uses a carcass of  plywood and teak faced plywood to form the exposed joinery. You can see here how the carcass is glassed onto the superstructure using  900Gm2 angles.

 

 

 

 

 

 

 

Right you can see a lower fore cabin positioned galley with the navigators station glassed onto the superstructure (top of picture) note the holes are to give access to the railing stanchion bolts.

 

 

 

 

 

 

 

Here is another example of main carcass work, where plywood is gassed onto the superstructure (under the front windows). the navigators seating, helm console and seat pedestal are built.

 

 

 

 

 

 

 

 

Another picture, this time of High Velocity showing b/heads glassed into the superstructure and plywood carcassing.

 

 

 

 

 

 

 

 

 

 

 

 

This is a very early picture of High Velocity showing the fore cabin being constructed.

 

 

 

 

 

 

 

 

 

Here is a picture looking aft showing a galley being built.

 

 

 

 

 

 

 

 

 

 

Another picture showing a helm console and seating under construction.

 

 

 

 

 

 

 

 

 

 

Here is a picture of Predator III under construction, a motor yacht superstructure with most of the wood work completed. Note the batons being erected on the roof ready to take the headlining panels.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Once the wood work has been completed work can begin on the sidelining. All the exposed GRP and  plywood is covered in sidelining carpet which is glued on.

 

 

 

 

 

 

 

 

 

 

Carpeting the fore cabin, showinhg the v berths built in plywood and sheathed with  600GM2.

 

 

 

 

 

 

 

 

 

Caterpillar C12 engine being lifted up and the boat maneuvered on the build trolley to drop the engine in the hull.

 

 

 

 

 

 

 

 

 

The engine positioned, sitting on 100x150mm 10mm steel angle iron bolted to the engine bearers with 6no 16mm bolts. The engine feet are then bolted to the angle steel with 14mm bolts.

 

 

 

 

 

 

 

 

Twin engine installation, in this case the engine feet sit on the engine bearers which have been built up to the correct height and angle and had 10mm steel encapsulated with 1800gm2, which are then taped with M14 tap allowing the engine feet to be bolted to the bearers.

 

 

 

 

 

 

The stern gear, (here shown the 'p' bracket and rudder tube are glassed into the hull with at least 4 layers of 900gm2.

 

 

 

 

 

 

 

 

 

 

Plywood reinforcement webs are fabricated and encapsulated with at least 2 layers of 900gm2

 

 

 

 

 

 

 

 

 

 The hull cutouts are useful for showing the thickness and strength of the hull, as can be seen here.

 

 

 

 

 

 

 

 

 

 

 

The gel coat is completely sanded off under the hull over the area to be glassed and the the stern tube is glassed in with 2 layers 900gm2. The p bracket cut out is filled, then a thin bead of silkaflex is applied between the GRP hull and the brass p bracket. This is to ensure no water can enter the laminate through the GRP separating from the brass minutely over time. 

 

 

 

 

 

 

 

A layer of 900 the encapsulates the silkaflex.

 

 

 

 

 

 

 

 

 

 

The deck beams are completed around the engine to the dimensions of the hatch opening.

 

 

 

 

 

 

 

 

 

Here is another example of a completed deck structure, this time on High Velocity.

 

 

 

 

 

 

 

 

 

Here stainless steel fuel tanks are fitted and bolted to the b/head, the deck structure is constructed over the tanks.

 

 

 

 

 

 

 

 

 

 

Here the exhaust system is being fitted. Where the exhaust hose passes through a b/head a Halyard Marine GRP elbow or straight connector is glassed into the b/head.

 

 

 

 

 

 

 

 

A water trap is used in this installation

 

 

 

 

 

 

 

 

 

 

 

The aft deck is laid. Plywood is laid on top of the deck beam structure, bedded on silkaflex and screwed down every 6".

 

 

 

 

 

 

 

 

 

The deck is then sheathed with 900gm2, the hull to deck join is bonded with 1800gm2 and extended at least 6" up the hull sides.

 

 

 

 

 

 

 

 

The gunwales are then flow coated with light aircraft grey and the deck coated with non slip.