Manufacturing Process

Ocean Yachts begin their life in the Mold Room — with the fiberglassing of the hull and deck molds. The deck mold includes the cabin. Molds are release-waxed, then Gel-Coated. Gel-Coat is the glossy white "skin" you see on the outside of the boat. Hull and deck are fabricated simultaneously.

Fiberglass fabrics are "laid-up" over the dried Gel-Coat, then saturated — or "wet-out" — with resin. Divinycell sheets are bonded to the Gel-Coat for reinforcement. The layers of fiberglass are what give the boat its strength. Cloth and resin are worked with metal rollers to create a durable bond.

A system of stringer support beams reinforces the hull. Bulkheads are pre-cut and drilled for plumbing, exhaust and electrical systems; then fastened to the hull with fiberglass tape.

The finished hull is removed — or "popped" from its waxed mold; then raised by overhead crane and moved up the production line.

The hull bottom is coated with primer to seal the Gel-Coat and painted to discourage fouling. The hull will be finished later in the owner's choice of color.

Next, the running gear is aligned and fastened to the hull.

Fuel and water tanks are installed while the boat is prepared for the installation of additional systems.

The powerful twin diesels are lowered into the engine room and fastened onto the mounts. Wiring and plumbing are already in place.

The exhausts are installed next; and the hull is nearly ready to meet its deck — which has been popped from the deck-and-cabin mold and is now ready to receive the wooden module that will form the staterooms and heads. Ocean Yachts was the first production yacht builder of large boats to use a modular system in the construction of below-deck living areas. This practice reduces manufacturing time and, ultimately, cost.

The module, with electrical and plumbing connections already built in, is attached to the underside of the deck. Windows are sealed and trimmed. And the module lowered into the hull as finish carpentry and trim work begin on the interior. The hinged transom gate is installed.

The flying bridge is assembled. Gauges, instruments and hardware, together with some of the electronics, are installed, then the hardtop, is added. And another Ocean Yacht is ready to launch on the Mullica River.


Photo of C. P. Leek
Building an Ocean Yacht

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The Ocean Yachts Movie

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