The making of an Essex 28 Fusion

Taping and painting

In manufacturing a performance boat the process may appear to be out of order. Especially in relationship to the painting process. Unlike most products where you first manufacture the part, then you paint the part you made. When it comes to the gelcoat process at least in the performance boat arena you paint the product before it has been made. In the pictures below you can see tape on the mold itsself. This is the graphic design you will be seeing on the finished product. The mold is taped and painted then the lamination happens afterward. After the lamination process the hull is then pulled from the mold as the gelcoat slides away from the mold and adhears to the fiberglass creating the finshed part. the mold is waxed to assist in the separation process.


Essex is well known for the quality of the gelcoat design and finish. there are tricks and a need for artistic qualities in the gelcoat finish that have been proprietary to essex boats for over 25 years.

Show More

Lamination

Laminiation is the next process to the gelcoat. This is where the fiberglass is hand laminated on to the fully gelcoated mold. The process is time consuming and detailed.The Resins and fiberglass is top grade.  From Vinyl ester resin to quadaxial roving Essex spares no expence. Each layer is hand formed into the part as the one lamiation cures the next is lay on top of it. this process takes around two weeks.

Lamination is an important part of the manufacturing of a boat. The timing and the art of this process is largely understated. . It is the overall structure and yet so few consumers find this process of any interest. Essex has alway been known for it wall constructed hulls. This is because we spare no expense building our hulls using the fines quality materials with an attention to structural integrity  This hull construction is a major treason why an Essex boat feels as solid and comfortable as it does underway.

Pulling the hull

After the hull has cures it is now time to pull the part from the mold. This can be easy or take some time depending on the waxing and the amount of parts released frion the mold. The more the mold has been used the easy it tis thriugh time. The process is to pull up with two hhoists or two forklifts. usually a chain is bolted in and connected to the forklift. lifting up you hear that famillular sound of the hull releasing from tthe hull. and there you have it for the first time you are able to see the colors and design.

Big Title

Fitting and bonding

Page Title

The deck is then fit to the bottom blocks placed all around the hull. This process will make sure the deck and bottom are precisly aligned. once this deck and bottom are in alignment the boat is ready to bond. Using a combination of roving and matt. specially cut for this projet from th inside the hull is bondedall arounf the outside of the boat. Bonds are placed in the liner area but in the liner to the floor area a special bonding material is used to insure a secutre bond but has a kindof rubbery texture giveing the deck a solid but rubbery movenment reducing creaking cracking and chatter that could occure usinf fiberglass alone.

1/2

Sand and buff

The deck is then fit to the bottom blocks placed all around the hull. This process will make sure the deck and bottom are precisly aligned. once this deck and bottom are in alignment the boat is ready to bond. Using a combination of roving and matt. specially cut for this projet from th inside the hull is bondedall arounf the outside of the boat. Bonds are placed in the liner area but in the liner to the floor area a special bonding material is used to insure a secutre bond but has a kindof rubbery texture giveing the deck a solid but rubbery movenment reducing creaking cracking and chatter that could occure usinf fiberglass alone.

Show More

Motor fitting for deck and transom setup will be removed for transom layout. Making good time. 

July 30th Thursday