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Marine Projects
The best way to show you what we do as mobile GRP specialists is to give you examples of projects that we've worked on. Below are a series of case studies, walking through each project to give you an idea of the process involved. Take a look at the services area of our website for more information on what we do and by all means get in touch if you have project in mind - however challenging it may seem; we've worked on projects from simple repairs to start-to-finish creations and enjoy the variety.
72ft French Motor Yacht
The 72ft MY "OCTAVIAN"
72ft Motor Yacht
This motor yacht in France had a manufacturing problem
Lamination
Here's the area laminated, back-up filled and faired and then the colourmatch gel coat applied, rubbed down and polished
Starboard side
Starboard side quarter damage
Badly repaired previously
This shows the terrible previously repair: no fibreglass; just filler. I had to fill and fair and then colourmatch
Polished
Here's the damaged stern quarter all repaired and gel coat colour matched, rubbed down and polished
Side deck
The door aperture had no fibreglass on it - it had cracked and fallen apart
Good as new!
Here's the side deck door aperture all finished and as good as new
The 72ft MY "OCTAVIAN"
72ft Motor Yacht
This motor yacht in France had a manufacturing problem
Lamination
Here's the area laminated, back-up filled and faired and then the colourmatch gel coat applied, rubbed down and polished
Starboard side
Starboard side quarter damage
Badly repaired previously
This shows the terrible previously repair: no fibreglass; just filler. I had to fill and fair and then colourmatch
Polished
Here's the damaged stern quarter all repaired and gel coat colour matched, rubbed down and polished
Side deck
The door aperture had no fibreglass on it - it had cracked and fallen apart
Good as new!
Here's the side deck door aperture all finished and as good as new
The 72ft MY "OCTAVIAN"
72ft Motor Yacht
This motor yacht in France had a manufacturing problem
Lamination
Here's the area laminated, back-up filled and faired and then the colourmatch gel coat applied, rubbed down and polished
Starboard side
Starboard side quarter damage
Badly repaired previously
This shows the terrible previously repair: no fibreglass; just filler. I had to fill and fair and then colourmatch
Polished
Here's the damaged stern quarter all repaired and gel coat colour matched, rubbed down and polished
Side deck
The door aperture had no fibreglass on it - it had cracked and fallen apart
Good as new!
Here's the side deck door aperture all finished and as good as new
The 72ft MY "OCTAVIAN"
72ft Motor Yacht
This motor yacht in France had a manufacturing problem
Lamination
Here's the area laminated, back-up filled and faired and then the colourmatch gel coat applied, rubbed down and polished
Starboard side
Starboard side quarter damage
Badly repaired previously
This shows the terrible previously repair: no fibreglass; just filler. I had to fill and fair and then colourmatch
Polished
Here's the damaged stern quarter all repaired and gel coat colour matched, rubbed down and polished
Side deck
The door aperture had no fibreglass on it - it had cracked and fallen apart
Good as new!
Here's the side deck door aperture all finished and as good as new
The Build of a Bulkhead in Jersey
Joining
The panels are joined in situ
Scribing
The panel is scribed to shape and marked-up to be routered
Routered edge
The edge has been routered ready to be joined
Adding on a bit!
An 8ft x 4ft sheet isn't quite wide enough - had to add another section to the side
Door cut out
The door is cut out ready for the installation - this then allowed me to assess the extent of the surface to be re-worked
My way
I chose the best way of carrying out the job in limited space available. The alternative, to make a female mould would entail a similar process
Making headroom
In this area I made a box section to create headroom for the area below
Making headroom Part 2
Here's the box section made to create headroom for the area below
Lamination
All panels have been laminated with 600g csm (chopped strand mat) on the face side and the back of each panel. In this way, there is no chance of cracking
Interior Face
This picture shows the interior face with 3x 600g CSM applied
The Surface
The surface was filled with reinforced filler that I mix up myself with chop strands and colloidal silica power mixed in with the white gel coat
Gel coat application
Once the filler had been rub down flat and fair I then applied 5 layers of white gel coat, feathering each layer so as to avoid a solid edge making it easier to rub down
Applying a Guide Coat
A guide coat was then applied to ensure that the surface is kept flat and true. It also helps to show up any scratches when going through the abrasive grades 120-1200
The Guide Coat
Here's the guide coat, all ready for sanding
Joining
The panels are joined in situ
Scribing
The panel is scribed to shape and marked-up to be routered
Routered edge
The edge has been routered ready to be joined
Adding on a bit!
An 8ft x 4ft sheet isn't quite wide enough - had to add another section to the side
Door cut out
The door is cut out ready for the installation - this then allowed me to assess the extent of the surface to be re-worked
My way
I chose the best way of carrying out the job in limited space available. The alternative, to make a female mould would entail a similar process
Making headroom
In this area I made a box section to create headroom for the area below
Making headroom Part 2
Here's the box section made to create headroom for the area below
Lamination
All panels have been laminated with 600g csm (chopped strand mat) on the face side and the back of each panel. In this way, there is no chance of cracking
Interior Face
This picture shows the interior face with 3x 600g CSM applied
The Surface
The surface was filled with reinforced filler that I mix up myself with chop strands and colloidal silica power mixed in with the white gel coat
Gel coat application
Once the filler had been rub down flat and fair I then applied 5 layers of white gel coat, feathering each layer so as to avoid a solid edge making it easier to rub down
Applying a Guide Coat
A guide coat was then applied to ensure that the surface is kept flat and true. It also helps to show up any scratches when going through the abrasive grades 120-1200
The Guide Coat
Here's the guide coat, all ready for sanding
Joining
The panels are joined in situ
Scribing
The panel is scribed to shape and marked-up to be routered
Routered edge
The edge has been routered ready to be joined
Adding on a bit!
An 8ft x 4ft sheet isn't quite wide enough - had to add another section to the side
Door cut out
The door is cut out ready for the installation - this then allowed me to assess the extent of the surface to be re-worked
My way
I chose the best way of carrying out the job in limited space available. The alternative, to make a female mould would entail a similar process
Making headroom
In this area I made a box section to create headroom for the area below
Making headroom Part 2
Here's the box section made to create headroom for the area below
Lamination
All panels have been laminated with 600g csm (chopped strand mat) on the face side and the back of each panel. In this way, there is no chance of cracking
Interior Face
This picture shows the interior face with 3x 600g CSM applied
The Surface
The surface was filled with reinforced filler that I mix up myself with chop strands and colloidal silica power mixed in with the white gel coat
Gel coat application
Once the filler had been rub down flat and fair I then applied 5 layers of white gel coat, feathering each layer so as to avoid a solid edge making it easier to rub down
Applying a Guide Coat
A guide coat was then applied to ensure that the surface is kept flat and true. It also helps to show up any scratches when going through the abrasive grades 120-1200
The Guide Coat
Here's the guide coat, all ready for sanding
A Series of Storm-damaged Boats in the British Virgin Islands
Filled and faired
This is just one of many hurricane-damaged catamarans that I've worked on, spending 9 months helping the moorings charter company in the British Virgin Islands (BVI)
Filled and faired
Next, the the hull is filled with epoxy and faired
Preparation of the Hull
Here you can see a hull that has been spray gelled and a guide coat applied ready for the fairing to take place
Finished
Here's a shot of the hull all finished with the decals added
More repairs
More areas that had to have repairs structually sorted
More areas
Down to the core
This catamaran had all of the damage cut out, the core replaced and had laminate vacuumed on to be faired
Filled and faired with epoxy filler
Filled and faired with epoxy filler
Area filled and faired with epoxy filler the tent was put up to shade us from the blistering heat
Filled and faired with epoxy filler
The area finished
Job complete
Here's a final shot of the hull all finished. Who'd suspect that this vessel ever had extensive damage?!
Filled and faired
This is just one of many hurricane-damaged catamarans that I've worked on, spending 9 months helping the moorings charter company in the British Virgin Islands (BVI)
Filled and faired
Next, the the hull is filled with epoxy and faired
Preparation of the Hull
Here you can see a hull that has been spray gelled and a guide coat applied ready for the fairing to take place
Finished
Here's a shot of the hull all finished with the decals added
More repairs
More areas that had to have repairs structually sorted
More areas
Down to the core
This catamaran had all of the damage cut out, the core replaced and had laminate vacuumed on to be faired
Filled and faired with epoxy filler
Filled and faired with epoxy filler
Area filled and faired with epoxy filler the tent was put up to shade us from the blistering heat
Filled and faired with epoxy filler
The area finished
Job complete
Here's a final shot of the hull all finished. Who'd suspect that this vessel ever had extensive damage?!
Filled and faired
This is just one of many hurricane-damaged catamarans that I've worked on, spending 9 months helping the moorings charter company in the British Virgin Islands (BVI)
Filled and faired
Next, the the hull is filled with epoxy and faired
Preparation of the Hull
Here you can see a hull that has been spray gelled and a guide coat applied ready for the fairing to take place
Finished
Here's a shot of the hull all finished with the decals added
More repairs
More areas that had to have repairs structually sorted
More areas
Down to the core
This catamaran had all of the damage cut out, the core replaced and had laminate vacuumed on to be faired
Filled and faired with epoxy filler
Filled and faired with epoxy filler
Area filled and faired with epoxy filler the tent was put up to shade us from the blistering heat
Filled and faired with epoxy filler
The area finished
Job complete
Here's a final shot of the hull all finished. Who'd suspect that this vessel ever had extensive damage?!
Storm-damaged Boats in the British Virgin Islands - 5800 Catamaran flybridge
Flybridge damage
On the flybridge a hole was discovered in the plastic teak decking which afte investigation turned out to go right through the laminate
More discovered
The area was cut out and revealed a large amount of water ingress
Water damage
I pushed my tool into the area to show the water in the balsa cored - this needed to be removed
Water damage
An area that we needed to cut out due to water ingress
Cut out
The saturated core material is completely cut out
Area prepped
The area is now ready for the first layer of chopped strand mat (CSM)
Next step
Here's the area with the first layer of fibreglass applied
Bigger than we thought
After investigation, we realised that the whole of the fly bridge floor needed repair
Several areas needed repair
The damage was extensive
Work was underway
The whole project
The whole fly bridge floor had to be taken up, recored and laminated under vacuum
Core materials
New core material was vacuumed down ready for final layers of fibreglass
First layer
Here's the first layer of fibreglass applied
Final layers
Final layers were applied under vacuum
Fibreglass layers
Final layers of fibreglass were applied and vacuumed. The area is now ready for screeding with epoxy filler
Epoxy filler is applied
Epoxy filler is applied
After the filler
The Flybridge filler was finished - next step, epoxy primer was to be applied
Sanding Down
The epoxy filler was sanded down ready for an epoxy primer
Epoxy primed
Here's a closer shot showing the epoxy primer
Primer
The epoxy primer was applied
Primed
Here's the flybridge floor with with epoxy primer
Flybridge damage
On the flybridge a hole was discovered in the plastic teak decking which afte investigation turned out to go right through the laminate
More discovered
The area was cut out and revealed a large amount of water ingress
Water damage
I pushed my tool into the area to show the water in the balsa cored - this needed to be removed
Water damage
An area that we needed to cut out due to water ingress
Cut out
The saturated core material is completely cut out
Area prepped
The area is now ready for the first layer of chopped strand mat (CSM)
Next step
Here's the area with the first layer of fibreglass applied
Bigger than we thought
After investigation, we realised that the whole of the fly bridge floor needed repair
Several areas needed repair
The damage was extensive
Work was underway
The whole project
The whole fly bridge floor had to be taken up, recored and laminated under vacuum
Core materials
New core material was vacuumed down ready for final layers of fibreglass
First layer
Here's the first layer of fibreglass applied
Final layers
Final layers were applied under vacuum
Fibreglass layers
Final layers of fibreglass were applied and vacuumed. The area is now ready for screeding with epoxy filler
Epoxy filler is applied
Epoxy filler is applied
After the filler
The Flybridge filler was finished - next step, epoxy primer was to be applied
Sanding Down
The epoxy filler was sanded down ready for an epoxy primer
Epoxy primed
Here's a closer shot showing the epoxy primer
Primer
The epoxy primer was applied
Primed
Here's the flybridge floor with with epoxy primer
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