The hull was built using the SCRIMP process. Chuck Paine provided the laminate schedule which specified the thickness and angle of orientation for each layer of E-glass. The various layers of E-glass are put in place on either side of the A-rated Corecell, while dry. Then piping for the resin is laid in horizontal strips separated vertically by about 18". This is all encased in an air tight plastic wrap and a vacuum is applied at the top edge. The magic moment is when the hoses are led to buckets and drums of Derakane 8084 vinylester resin and the clamps removed to allow the resin to flow. The resin is drawn up into the pipes and saturates the materials while slowly moving up the hull. Two months of works comes to fruition in a few hours and 24 hours later a new hull is ready for the next steps. After adding various longitudinal and athwarship stiffeners, the mold was split in half and the hull was lifted out.
Mars Metals built the keel from a CAD file supplied by Chuck. Mars built a mold, positioned the keel bolts, and filled the mold with 17,000 lbs of lead. It arrived at Lyman-Morse and the hull dropped onto the keel bolts without hesitation. It doesn’t get much better than that!