New Morning » Deck and Dodger

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The deck is built entirely by hand. Like the hull, frames are built that capture the shape of the deck and the cockpit (with all it’s little coamings, turns and facets). Then the frames are planked and finished to produce a mold. Layers of fiberglass, then core (thought not in the high stress areas), then more fiberglass, are built over a series of days, allowing each layer to dry and cure before the next is applied. Then the deck is lifted out of the mold, flipped over while dangling from a crane (a nervous moment!), and eventually transported to the main building to be mated with the hull.

The process with the hard dodger is essentially the same, but it’s much smaller and has fewer facets.

The most recent pictures show the painted deck with the non-skid applied. The glossy areas at the edges, around the hatches and around hardware show where the non-skid was not applied.