Palm Beach Hull Construction - 5 Pages

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Catalogue excerpts

Palm Beach Hull Construction We often get asked at Palm Beach why our boats are significantly lighter than similar sized fibreglass boats built by other manufacturers. When Mark Richards founded Palm Beach Motor Yachts he brought with him a construction culture born from a yacht racing background. He realised that despite the availability of better, more effective hull construction processes, most other leisure boat manufacturers were not adopting them. His fresh picnic-boat design, yacht racing construction technology and obsessive pursuit of perfection, set Palm Beach apart. Since we started building boats in 1995, Palm Beach has been building boats, the majority of other leisure boat manufacturers have not adopted similar building processes. So what do we do? 1) We coat the inside of the mould with a hard wax to stop the hull from bonding with the mould. 2) We then start the hull from the outside and work inwards (as a female mould dictates). The outside of the hull is a material called Gelcoat which, is a modified polyester resin. This material is relatively soft and can be sanded and buffed to a superb finish and provides resistance to ultra violet light and hydrolysis. Gelcoat does not require painting but most owners opt for a classic Palm Beach individual colour finish, by painting the hull with a urethane paint. Gelcoat can be pigmented but does not have the same visual finish as a high quality paint. Gelcoat hulls are generally white or derivatives of, such as cream or grey. This layer when complete is around 1 mm thick. 3) Once the gelcoat has been sprayed on and allowed to cure, the first of the required (3-5) layers of fiberglass is hand laid. Each layer is stitched eglass which is a type of fibreglass cloth. The cloth is pre cut before arriving at our factory and lays into the hull like a jigsaw Palm Beach Motor Yachts 50 Newbridge Road Berkeley Vale . NSW 2261 Australia T: 61 2 4389 1244 F: 61 2 4389 1911

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puzzle. This ensures that the correct amount of cloth is used in a boat and that none is wasted by the factory and that each hull is identical in weight. 4) The cloth is mixed with vinylester resin to form fibreglass as it cures. 5) Once we have the required layers of fibreglass inside the Gelcoat, we put down a layer of Corecell foam. This material is highly resistant to moisture and heat, it’s very light and has excellent sheer elongation properties. Its primary purpose is to be the meat in the sandwich and therefore create a robust space in order to construct a panelling effect in the hull...

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Stage 1 of construction involves preparing the mould to ensure a mirror smooth hull. Stage 2 right: involves spraying the gellcoat into the mould to create the external hull finish. Below: the infusion process bonds the stringers or longitudinals into the hull. Utilising this technology reduces weight and build time while increasing strength.

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All panels, bulkheads and tanks are bonded into the hull to reduce weight and increase stiffness and longevity.

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There is a large amount of hand crafting that goes into creating a Palm Beach finish

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