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Two more build slots are available for delivery mid April and end of May respectively. Boat one is being configured principally for offshore racing and will feature a water ballast tank system designed to reduce the crew numbers to 7 or 8. However, Carkeek Design Partners and FIBRE Mechanics are making a wide range of equipment options available allowing subsequent boats to be configured to suit different racing programmes.
Preliminary details indicate a full on approach to the hull build, with Waterfront Composites specifying full IM carbon and honeycomb core throughout. Detailed specifications and pricing for the standard boat are due for release on Sept 18th. The Superstructure will be installed onto a 20m aluminium hulled SES catamaran wind farm service vessel, due to enter service in the North Sea by the end of the year The structure was designed to be built without the expense of making production moulds.
The entire structure was moulded on high temperature vacuum tables using Gurit's fire retardent pre-preg epoxy resin system and glass fibre re-inforcement.
The panels were then assembled on a simple alignment jig and bonded together. Areas where curvature was required have single curvature only, so that the boat builders at FIBRE Mechanics were able to bend and in some cases fold the cured panels to the shape required.
The superstructure incorporates the sole and undersole structure that will be resiliently mounted on the deck of the ship. Also incorporated into the panels are the seat mounting fixtures to make the fit-out of the superstructure as efficient and fast as possible.
The delivery of components is timed to co-incide with the completion of the hull, so that the assembly teams can get to work building the boat without breaking stride. William Jelbert is the Project Manager for the GB, and was responsible for the development of the boat and the key decisions about the production process.
Once the key structural elements were designed, the rest of the internal structure could be optimized accordingly. We weighed the option of outsourcing these advanced components to an industry partner. A breakthrough came when FIBRE Mechanics presented us with the opportunity to employ robotically-laid fiber to the structural components on the Gunboat 68 i.
This is the same technology that produces aircraft tail fins and F1 car parts - structures with incredibly demanding engineering tolerances - and the quality is just exceptional! Thin ply pre-pregs allow greater optimization of modulus, strength and weight, and an overall improvement in the mechanical performance of the final part.
This repeatable and automated process can handle very fine laminate details. This opened up opportunities for our engineers, as decisions on the internal structure and ultimately performance gains could be further optimized The hull is built entirely in High Modulus carbon fibre with aramid honeycomb core, and cured at 95 degrees centigrade in a 35m long hull oven.
This is all fairly routine for FIBRE Mechanics, the only remaining challenge being to navigate some tight corners in Lymington and a few tricky roundabouts in Lorient. The oven was designed by the in-house project team who bring a great deal of experience to the task. Gary Vaughan Director of Operations commented " This new oven has come together far quicker than that one, and requires a lot less energy to get up to temperature.
It's good to see we have learned something over the years The new oven has been built over-length so that it can be sectioned into smaller units as required. At present it is partitioned to provide a 14m oven for two large vacuum tables where FIBRE Mechanics are building the structural bulkheads of the Gunboat 68; and a 34m oven currently being prepared to accommodate a new project starting late August.
The oven is powered by electric heaters capable of raising the temperature to degrees centigrade - with both temperature and vacuum pressure being controlled, monitored and logged across all component surfaces. Fifteen separate heat inlets allow accurate control of temperature at every point within the oven; and a retractable roof allows use of the overhead factory crane during hull assembly.
Having agreed to construct the boats just 12 months ago, the team at FIBRE Mechanics successfully completed a complete set of production tooling and 10 boats in the space of 9 months.
The 10 boats from FIBRE Mechanics together with the club's existing 10 boats make up a fleet of 20 one-design 37ft racing boats, available to Club members to compete in one of the most competitive and intense one-design racing programmes yet seen. All 20 boats have been built to exacting standards to ensure that the weight, and weight distribution of each is identical. The kg carbon keel fin and lead bulb assemblies are corrected to within a single kg, and all deck gear, sails, rig and sailing systems adhere to a strict one-design specification drawn up by Mills Design in close consultation with Harry Melges, and drawing on the experience of an all-star committee of top sailors from the NYYC.
Fibre Mechanics is based in a purpose built yacht manufacturing factory in Lymington, UK. We build custom racing yachts and semi-custom performance yachts of the highest quality. Our Design and Technical Office specialise in design and installation of lightweight systems and interiors Read More.
We are an employee-owned company with a strong workforce divided between Project, Production, Engineering and Design teams. All are dedicated to the construction of lightweight composite yachts, and are able to call on many decades of experience in the racing yacht industry.
Every member of our management and production staff has a stake in the company and brings a combination of experience, judgement and motivation that we value More often than not, the weight saved by building in carbon is 'given away' by the installation of a less-than-lightweight interior.
The success of a performance yacht depends on a consistent approach to saving weight. For each loaction within a yacht there should be an acceptable marginal cost for the saving of a kilo; and this has to be respected by the design and production teams at every level Meanwhile we cut whatever core material is being used on a cnc router, and then incorporate carbon inserts to re-inforce cut-outs and penetrations.
When we have completed both the skin and core kits, we use a laser projector set up in the roof of the factory to project the location of each component of a panels' jigsaw puzzle piece by piece. When the panel is complete we apply a vacuum bag and set the oven to cure Read more. An efficient boat yard must be capable of using the most appropriate technology for each Yacht Builders Lymington Junction part of every process.
This demands that we are able to apply a range of composite process techniques to a yacht project. For a fully optimised and engineered structure we will use automated pre-preg techniques to provide the quality assurance required. For a mid-level production hull we'll use one of a number of film or resin infusion techniques. We often use a number of approaches to build different components on the same project Alongside every yacht project are a variety of small and not so small component projects - to the point that we have a full-time specialist team building critical components such as carbon keel fins, rudder shafts, chainplates and lifting beams.
There are also numerous components that may not be as critical in a structural sense, but need to fulfil cosmetic requirements. Carbon composite components form an important part of our work The Melges IC37 Class was developed to create a racing experience unlike any other. The boat itself is innovative, elegant and simple. One set of 3 sails for all conditions, a rig designed to trim and go, no extra instruments. And yet, remarkable performance in all conditions. But the IC37 is more than just a new boat.
It is an innovative amateur one-design class designed to race with a crew of family and friends. N ews Gunboat 68 Hull 5 Delivered. Photo: Onne Van Der Wal. Approach More often than not, the weight saved by building in carbon is 'given away' by the installation of a less-than-lightweight interior. Panel Factory In nine lines, this is how our panel factory works Technology An efficient boat yard must be capable of using the most appropriate technology for each part of every process.
Components Alongside every yacht project are a variety of small and not so small component projects - to the point that we have a full-time specialist team building critical components such as carbon keel fins, rudder shafts, chainplates and lifting beams. Information page to follow shortly
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