Bonding putty is evenly spread on the hull and foam core is laid on top. Mesh is arranged on top to allow air to be suctioned out from behind a plastic envelope that is applied next. The outer edges of the plastic are then sealed and secured.
When suction is applied to the plastic envelope, 14 lbs/square inch of pressure is applied by the atmosphere, pushing the core firmly against the structural layers. The air travels out through the pinholes in the foam to ensure a secure bond that’s free of any air pockets. This vacuum bagging process assures a 100 percent bond between the structural layers and the core.
We don’t use foam core below the turn of the bilge. Should damage occur below the water line, the solid fiberglass is more easily repaired. Solid fiberglass also facilitates high integrity thruhull installations.
We use a hand layup method to apply all our fiberglass (no chopper gun used). Hand layup requires less resin and results in a lighter, stronger boat.