The process starts with waxing the molds. The deck mold is being detailed for the new boat. On the 17 foot model the non-skid is part of the mold and shall be the same color as the deck. On our other models the non-skid may be custom ordered to a color of your choosing.

The white gelcoat is sprayed into the waxed hull mold.

After the blue gelcoat, the first laminate of fiberglass is carefully applied.

The gell coat has been sprayed into the mold and the first layer of fiberglass cloth has been laminated onto the gelcoat. You can see the balsawood core pieces ready to be placed onto the deck.

The balsa core is being laminated to the outer glass with a vacuum bag process at 11 pounds negative pressure.

The core has been vacuumed bagged into the hull mold and several strips of carbon fiber have been laminated in the hull. You can see the bulkhead being placed at the front of the cockpit.

Some additional D10 tabs at the rudder post at the back of the cockpit.

The beautiful blue hull popped right out of the mold. We admired the flawless two tone gelcoat job for a few minutes before starting the process of bonding the deck to the hull.

Thursday, Feb.20---We popped the deck out of the mold. There is nonskid on all horizonal surfaces. On the seats and cockpit floor, the nonskid wraps around to the vertical surfaces. Because of this sometimes it is very difficult to just pop it out with out some minor gelcoat damage, but this time the deck came out perfect.

You may be able to see the non skid. The deck is ready to bond to the hull.

The deck is now bonded to the hull. The hull remains in the mold during this process You may see the excess hull, to be trimmed off, extending beyond the deck. At this point we are having the trailer built.

Carlos is checking the rig, making sure all the fittings are correct. The mast weights around 18 pounds (8.2 K) and the wishbone boom an additional 8 pounds (3.6 K), the entire rig including the sail with full battens, halyard, reef, and sheet is only 42 pounds (19 K). However, the mast is 27' (8.25 M) and can be a handful if you are not careful of the wind and where it is being stepped.

The keel and rudder are ready to go. The rudder weighs 7 lbs. (3.2 kilos) and the keel about 407 lbs. (185 kilos). The rudder is state of the art, super strong foam filled laminates. The keel is lead with 6 1/2" (24mm) all thread stainless steel bolts that are about to be attached to the boat.

We can slab reef the sail by using the cunningham on the tack cringle and securing the clew to the back of the wishbone boom.

Tom and Dave place the sail hardware and adjust all the lines prior to putting the boat on her keel and shipment.

We put the boat on her keel on the trailer and are making some last minute gelcoat repairs prior to releasing for delivery.

The tiller and rudder are in place. The aft support for the mast and boom shall lock the tiller (and rudder) in place during transport. Looking very carefully at the photo you may see two strap eyes aft of the rudder post on the cockpit floor. The port side strap eye is where the main sheet ends and is tied off. The sheet is run through a block on the end of the mast, then through a block attached to the starboard eye strap.

The lifting ring is attached to the aft keel bolt, accessed through the deck plate on the cockpit floor.

A short line around the mast in addition to the cunningham keeps the pressure off the sail track.

You may see the double block and the lines tied off on the wishbone boom.

A last minute check, making sure all the fittings are, for sure really in place and ready to go.

Looking good, it takes about 5 to 10 minutes to drop and flake the sail, lower the wishbone boom onto the deck, pull the mast off the step and onto the deck. Then another 5 minutes to strap everything down for transport.

The day before the trip to Texas. Ready to roll.