Our Deck Construction Process

Our decks are the strongest and stiffest in the industry. Our custom vacuum infusion process creates the best resin-to-glass ratio, and all deck hardware is mounted through solid glass laminate with appropriate FRP or aluminum backing plates.

Built-in Strength and Longevity

This produces major benefits: decks of exceptional strength, stiffness and durability. This is the result of a 30% resin to 70% glass ratio rather than the 70% resin to 30% glass used in our competitors process. In this closed-mold system, fabric and treated balsa cores are cut and laid dry in the mold at one time. Then the vacuum bag is applied over the laminate and air is evacuated to achieve one atmosphere of vacuum pressure. Resin feed lines are opened and atmospheric pressure forces the catalyzed resin into the laminates, completely saturating the dry glass and balsa cores.

Superior Physical Properties

The consistently high glass-to-resin ratio produces very high physical properties of stiffness and strength. Eliminated are the inconsistencies of labor-intensive hand lay-up that's dependent on the individual laminator's skills and it does away with air entrapment and void problems that can compromise durability.

There are no voids that can fill with water, no paths for potential water migration through the core which is extremely important to boat owners who install aftermarket deck hardware and canvas goods. Owners also enjoy decks and cockpit soles that deflect substantially less under load and won't crush under localized impacts.

The Interior Structural Component

Keel timbers, mast step, chainplate attachment points, structural stringers and bulkheads—are bonded in place with fiberglass reinforcement and our unique proprietary BPA  epoxy resin. This Tartan construction technique provides greater strength in these critical structural elements than conventional construction techniques found in other boats. Tartan construction offers our owners the safest hulls in the industry.

All thru-hull fittings are installed in solid laminate (no core) preventing water migration into the laminate. Careful attention to detail is taken when installing all fittings to ensure laminate integrity, moisture resistance and safe operation. We use only 90 degree throw flush Marelon thru-hull fittings that are UL and ABS approved and corrosion-free, providing years of safe and trouble-free operation.

Our hull-to-deck joint is a time-tested structure consisting of an inward flange in the hull incorporating a 6061, T6 hardened aluminum backing bar. The resulting joint is bonded with 3M's sturdy 5200 adhesive sealant. This Tartan construction technique provides our owners the most secure hull-to-deck joint in the industry, and also allows serviceability from outside the boat.

The finest hardware and components from leading marine suppliers are mounted to the deck through solid laminate with stainless fasteners that are drilled and tapped into laminated-in-place aluminum backing plates. All hatches and ports are likewise installed through solid laminate. In areas where hardware is not affixed, select sealed coring is used to create a stiffer, lighter deck structure. The resulting weight savings in our Tartan decks provides a lower center of gravity with increased stability and an easier motion at sea.