The All New F-22 - Earlier
Latest Progress and Sailing Photos Now Are At:
All Progress and Development History Prior to September 2013:
August, 29th, 2013
ALMOST READY FOR SAILING
Main and jib now fitted and ready to go
Boomless main being roller furled around bottom batten, by winding the handle
The fully furled boomless mainsail makes a very neat and easy to handle package. Still a couple
Mast foot setup - the halyards cleat directly on the mast, and can also be led directly to either winch.
Being trailered...the micro car shown handled it surprisingly easily, but not really for the road......
The trailer is now our main holdup - waiting on the mudguards to be fitted, after which it can be checked
August 23rd, 2013
Today we setup and raised the F-22R carbon mast for the first time:
Fitting the mast raising system, which worked perfectly. Definitely needed with the tall 'R' mast.
Mast being winched up by trailer winch. Everything can be done single-handed, something
Mast now raised and roller furling jib being tried.
Stays are setup so that they are the same length in or out, and will always support the mast,
Wheels are still bare, but mold is almost finished and the fiberglass guards should be fitted in a
The Doyle boomless main now being tried.
...and now being roller furled. The roller furling gooseneck is not yet fitted so rolling had to be done
Still many little items to fit, finish and checkout before we go sailing, as I always like to have any
August 17th, 2013
The aluminum/composite trailer now nearing completion - it is almost too good to put a boat on.
Front is still waiting on the winch post/nose molding, but the drawing below details what it will look like:
The all composite trailer front molding as currently being built. The winch post will include
Wheels will have molded fiberglass guards, as below. Finally we have a trailer that is going to
The fiberglass wheel guard mold in process.
Meanwhile sails are almost finished at Doyle Sails in Auckland, mainsail shown.
Foot - tack area showing cutaway to allow for roller furling, and the large lower batten pocket
August 14th, 2013
Cockpit view, and showing why I am so keen on having the furlable boomless mainsail as standard.
Not too many photos this update, as it is full speed ahead at present to get this first boat launched. Trailer
July 28th, 2013
Trailer assembly started, with anodized aluminum side channels now together, and polished alloy
Trailer bed, or shipping cradle will look like this, but without the wood cross webs and wheels. This
Carbon mast foot being assembled with rope clutches on each side.These can be pointed directly at jib
These very last stages are taking a while, but this is not the time to rush things or take short cuts, as I frequently advise home builders. Otherwise once launched, it is likely that the boat will never be quite right or finished properly. However, we are now on the last few parts such as aft and forward mast supports (for trailering), main hatch trim, and bow pole, so while things a a little busy here right now, I'm finally running out of parts to design. However, all such parts have to be documented properly, no matter how small, and once made, each part still has to be tried in position to ensure it will work well, be as simple as it can be, or if not, it may need redesign. Metal parts then need to be anodized, or electro-polished, both of which can take up to 7 days, so one has to be patient through what can be frustrating delays. But this has to be expected when setting up a completely new production boat, and the last batch of parts for anodizing should be sent off in the next few days, after which #1 can be finished, and out the door!
July 20th, 2013
A general factory view as at July 20 - the wing mast is now joined as can be seen in background, and we should be ready for the first trial set up and raising very soon. This has been quite a while in development as we developed and improved the building system, plus quite a few changes were made on the way with attachments, as we optimized the rigging and halyard systems. Roller furling components for the boomless mainsail have also been in development and these are almost ready to fit.
The trailer fiberglass tub can also be seen at center, still on the mold, and this will be removed and fitted once the aluminum trailer components come back from the anodizers and are bolted together. Two F-39 beams can also be seen at left, almost ready to ship, while boat #2 is just waiting for boat #1 to get out of the way.
The carbon wing mast almost ready - just needs final detailing and halyards etc fitted.
Interior looking aft - the interior of prototype is being left bare at present, as our priority is to get
Closeup - these backing nuts are tapped (threaded) aluminum cones, and have been custom made for the F-22.
July 9th, 2013 - The Trailer:
The F-22 trailer components starting to be assembled - trailers have always been a bit of an irritation in the past, as current trailers are not that much different from the galvanized steel trailers of the 1950s. The inevitable pressure to get boats out the door usually means just finding the best trailer that would do, so most previous boats went out on the same old galvanized trailers, which are really now outdated and rather clunky.
The original F-27 trailer was a little better, and looked fantastic when it first arrived with a glossy black painted frame and chrome plated wheels, but it was ungalvanized due to Californian environmental laws, which made galvanizing difficult and expensive. However, after three years it looked like junk, in spite of frequent fresh water washing, and it was no longer something to be proud of.
We then changed to another brand which was galvanized, but only by being sent to Arizona in parts, which were then assembled and bolted together back in California. However, I still remember hearing the groans and creaks that such trailers would make from flex as they went over uneven ground, and even though galvanized, they still started to rust too quickly, particularly at the bolts which were usually just zinc plated. A sad state of affairs, and it seemed a great pity to have to put a high tech boat like the F-27, on such a refuge from the fifties. Aluminum trailers were of course available, and used, but only at a much higher price which was hard to justify for many. The end result was a decision that any future boat I built would NOT be put on a galvanized trailer.
Thus the F-22 is going to come with a modern high tech trailer to match the boat, and while it will take longer to get it developed and setup for manufacture, it will be built very well, match the boat perfectly, and still look great in 10 years time.
Basic frame will be anodized aluminum, while wheels will be alloy, with fiberglass or plastic guards. The jockey wheel assembly is a high tech modern unit from aluminum, with a wide wheel to prevent digging in, while the winch is also aluminum, and will sit on a custom fiberglass molded post unit. The only steel parts will be the Duratorque axles, hubs and coupling, mainly because there are no stainless or aluminum alternatives available, or that I have found yet. However, the axle unit is heavily hot dipped galvanized, so it is unlikely to rust for a long time.
Stainless steel (316) fasteners will be used throughout, wherever possible, and every area of contact between stainless and aluminum or the galvanized axle will be insulated by a bedding compound or insulating plate. There will be no welding (too fatigue prone), and the whole trailer will just bolt together, with every join bonded with a strong flexible adhesive to ensure there is no corrosion or creaking.
Fitted in the frame will be a fiberglass tub molded to closely fit the boat, and incorporating carpet strips along the key support areas. Openings can be left for instrument senders or for daggerboard to pass through if wished. When retrieving, the fiberglass tub sides will guide the boat in making it virtually impossible for the bows to touch any metal part on the trailer which tends to cause scratches. This tub will also be used as the shipping cradle, but rather than throwing it away at the other end, one just bolts together the aluminum channel frame (which can come precut with the boat or the channel can be purchased locally). Then bolt on the wheel and winch units, and one has a modern corrosion free trailer, with nothing to throw away.
The steel cradle that was used to ship the original F-33 can be seen at Shipping Cradle and it did the job well. However it then had to be discarded and this will not be necessary with the F-22.
Where needed, the wheel/axle units and coupling can also be sourced locally so as to comply with local regulations, or for readily available local spares.
June 30th, 2013
Bow nets now fitted, with an all new bow pole system being developed. Number two boat in the
Daggerboard is now in place, with control lines fitted, and cleated on the carbon fiber mast step,
Wingnet to beam lashing detail, using the new alloy button lashing eyes.
Bow net side lashing - again no metal fittings making it very simple and with no corrosion issues.
Bow pole side support line - clean and simple
A bit of history - the original F-27 factory in 1987, about the same size, and probably around 9 months
We were producing just on one boat a month in 1987, and three years later it had reached two boats
We also do other things to help keep what can be very high development costs down, F-33 beam tops
June 4th, 2013
FIRST MAST STEP DETAILS
The molded carbon fiber mast step and foot are now made
and this is how it will work, with most controls on the step, so as to keep deck uncluttered. All the cleats
May 25th, 2013
The first F-22, now fully assembled, with only the mast and trailer needed to go sailing
Everything is designed just right - float and main hull have to be as large as they can for the maximum
Beams are curved just right at outer ends for maximum water clearance.
Stern view with extra long F-22R daggerboard rudder in place
Outboard tilted up, and with the bracket being located well to one side the prop can be lifted very
Outboard down and viewed from front
Outboard is located well forward for the best weight position, and where it works best. Bracket
The outboard could actually not be any further forward, being right at the end of the folded float. The 8HP
Access to motor is easy from cockpit, and even this big motor can be turned considerably either way for
Wingnets are easily the best system I have ever used. No metal parts required, other than some small
Note also, the complete lack of any intrusion of the forward beam into cabin - a major advantage of the
View from cockpit. Again, note how clean the beam to hull connection is, with minimal intrusion into
Main hull lashing detail with 40 stainless steel bolts having been eliminated. Lashing line wraps around a
Carbon chainplate in its own recess in wingnet molding, with custom Colligo deadeye fitted.
Clean bow area with flush anchor well hatch (again no metal fittings)
Anchor well with the optional Manson R4 Racer aluminum anchor in place. One of the optional
The mold for the all composite production cradles to use for supporting and moving hulls on the factory
Deck No. 4 Now Made
Deck #4 has been made this week and it went perfectly - our best yet!
A major update with many new photos will also be coming in a few days
with many of the details that you want to know - so watch this space!
Deck #3 is now out of the mold, and with none of the problems we had with #2 (as reported below), so
it will be used on hull #2. We have now also started work on F-22 #3, with many internal parts made
while the hulls are scheduled to be started next week.
Fiberglass hull cradle plug now made and on the way to being turned into a mold, from which
composite factory production and shipping cradles will be made. It should also be possible for the
shipping cradle to be converted into a road trailer after delivery, by bolting on local running gear.
More to come on this, as it could represent a big saving, not to mention a rust free light trailer.
Floats and beams now ready for final assembly to the main hull. Has turned out to be a very clean setup.
Close up detail of the finished outer aft beam area, which is easily the best configuration I have ever done.
A sample of the many building checklists currently being developed, with the 13 page Float Assembly
A well developed checklist system ensures that the boat is built correctly, and that nothing can be left out or
Final Fitout Starting For Boat No. 1
Non-skid now applied and fitout can finally begin
Floats and beams are also now non-skidded. Note the clean uncluttered decks and minimal deck hatches.
Mast Step mold is now complete and first all carbon step is being made this week.
March 31st, 2013
Third Deck Now Made
Will be used on boat #2 due to the infusion problems encountered with Deck #2, as described
The faulty Deck #2 is now cut up and being used as an alignment guide on hull #2 (in mold) for
Which immediately raised thoughts about what an interesting format this could be with a huge open cockpit.
Meanwhile our prototype sits patiently awaiting final fitout and the carbon mast, which is now being
Mast step and mast foot molds are also being made for the all carbon mast step assembly (no metal parts).
A set of F-39 beams are also under construction for another European buyer. F-22 daggerboard
Another feature of the F-22 with its third generation beams are the new wingnet lashing eyes, which
As with the F-33, the lashing eyes are well under the beam spray rails (join flanges), so that lashing gaps
No more lashing gaps! These latest style lashing eyes will also now be used on all
Meanwhile, local owner Rob Densem has been making us envious by sending in photos of sailing his
Looking north up the coast - photos were by Dick Borrett , a future local F-22 buyer, who also brought along
March 6th, 2013
The newly made all composite wingnet rail being trial fitted on boat #1, and carbon chainplate can also be
The rail blends into the aft beam perfectly. This area has been the source of some annoying spray that could
Float deck hatch - the use of a composite stiffening frame around the deck opening allows lighter plastic
First float for boat #2 being set up to join. The high volume/buoyancy located well forward is very
obvious, which makes the F-22 very stable and safe.
Our second deck is now out of the mold, and it initially looked good, but unfortunately a close inspection
The bottom line is that patience remains an important factor in seeing the F-22 through properly, in order to establish the right procedures, while sub-standard parts should not be accepted just to get boats out the door. Rushing the final details can ruin a project, and doing it right now means subsequent boats will be better and easier to manufacture. Even the above composite wingnet rail will not actually be used on a boat, as it can be improved even further in a couple of areas, so some small mold changes are being done. This takes time, but a better fit and finish means subsequent boats will go together easier, and boats can then be built faster (and better).
Building the second boat as we complete the first boat is also slowing things down, but we already know the first boat will sail great, so there's no need to rush it. Everything is ready to go, with just the non-skid to be applied, deck fittings to bolt on, and the only major items not ready are the carbon mast (in process) and the carbon mast step system (molds being made). However, once launched, the next few boats can then follow very quickly.
In contrast, when setting up Corsair Marine, we concentrated more on getting the prototype F-27 launched, so it was finished relatively quickly. But at that time nothing like it had ever been built or sailed before, so we were very keen to see how it went. However, the second F-27 then took another year to build, as little of the necessary and important preliminary production setup work had been done. Very few actual molds were completed (only around 6 in fact), whereas 57 were eventually required. This is not the case with the F-22, where 98% of the molds (37) have already been made.
Deck #2 Now Infused
February 25th, 2013
Deck #2 is now infused and only two float halves to go before all the major components for F-22 #2
The outboard well molding (requires a two part mold) - can you figure out how it will be used? Like many
Our test mast being tested - and yes we broke it! Learned a lot and the real thing for boat #1 is next.
Hull #2 Now Infused
February 16th, 2013
Our second hull is now resin infused, and this went very smoothly. The next item will be the deck,
Carbon Mast - First Photos
February 13th, 2013
We have been working on our own carbon mast for the F-22, which will be standard on the F-22R and
The mast sections are 100% carbon, resin infused under vacuum, and a big advantage of building in
This is also a very practical carbon mast, with none of the expensive aspects of many masts, such as
Meanwhile, in the factory, No #2 main hull is being built this week, with its deck to be done next week.
Boat #1 Now Joined And Folding
January 30th, 2013
First boat is now all joined up. This is the first ever of my designs that can be joined like this (without
Side view - the main advantages of being able to join without the deck are many more options with
Folds perfectly, as is usual
Stern view - add a foredeck, traveler plus an extended cockpit floor, and one could take it sailing like this,
We have now also started on building boat #2, with the first float being successfully infused today. Photo
First Deck Now Lifted Out
January 10th, 2013
The first production F-22 deck, now out of the mold and being turned over. Came out
Production Prototype Now In Assembly AreaF-22 Specifications And Options
(added December 31st 2012)
December 26th 2012
The hull is now in the final assembly area ready to be joined with beams and floats! One of the many
advantages of the new 'third generation' Farrier Folding System is that one can assemble the beams,
folding system, and floats BEFORE putting the deck on. This makes it much easier and quicker to do,
as one can avoid having to scramble in and out of the boat to fit and tighten the all the nuts inside.
The three bows from the side, with the spinnaker pole bow mount also visible
The deck will not be lifted out of the mold until our factory reopens on the 14th January, as it is now the
We may be tempted to lift the deck out, but probably not, as a steel lifting jig and holding cradle are both
Deck Construction Now Complete!
December 21st 2012
The deck now fully infused, and it took just on 2 hours
Resin infusion just started
The vacuum bag is now on and we are ready to go for it! Resin infusion will take place tomorrow morning.
First actual layer of fiberglass fabric now being fitted in place, which will be resin infused along with all
the other layers and core once in place and under vacuum
It is time to get the float molds out and ready again as we will need to start making more early next year
Deck Mold Now Complete!
December 13th 2012
Foam core is now fitted, complete with high density inserts at high load areas, such as winches or sheet tracks.
All foam pieces will now be removed, so that templates can be made, and eventually all these foam pieces will
be computer cut ready to fit, saving considerable time. We are now planning to re-gelcoat for the first deck on
Monday, and shoot for getting our first deck made before the Christmas break.
Deck mold now gelcoated, whereupon it is safe to walk on and foam core can now be trial fitted. This initial
layer is also used to condition mold, and will be removed once foam fit has been checked. Then the actual deck
gelcoat will be applied, followed by reinforcing and core, then resin infusion, and finally we will have a deck!
The foam core for the deck is now being cut using the plug as a guide, while the templates will also be
made at this time to cut foam for all subsequent decks. A fiberglass 'splash' or molding will next be made
over the deck plug, and this will then be fitted out as a drilling and cutting jig for use on all future decks.
Molding is then hung from the roof and just drops over a new deck, where it is used to drill all the fastener
holes for all fittings at once, and also used to cut out the window and hatch openings. If we had automotive
volumes then all this would be done by robots, but air operated automatic drills may also be a possibility if
we can get sufficient volume. All of which will make production that much more efficient.
A view of the finished deck mold from the stern. Another couple of days for waxing and we will then be
ready for the first sacrificial layer of gelcoat.
Deck Mold Now Complete!
December 6th 2012
The finished deck mold, now polished, sealed, and ready for waxing. Very simple, and
definitely the easiest to laminate deck mold that I have ever done.
December 4th 2012
Deck mold being prepared for lifting off the plug - can be a worrying time as occasionally the
mold can stick to the plug, which can be a disaster. Fingers crossed.
Getting ready to lift.
Small wedges are now being used to start the separation process at the bow.
Bow end is now completely free, while wedges are being used at the stern.
Stern now also free, so we can relax a little with no stick up problems.
Mold now completely clear of the deck plug!
Deck plug has been rolled clear, and mold is looking very good.
Now being rolled over.
Upright, wheels fitted, and the gelcoat will now be buffed and polished, after which mold will receive
5 or 6 coats of wax, which will all take another week - boat building can be a slow process at times.
But we will soon be able to build the first deck!
Deck Mold Reinforcing Now Going On
November 26th 2012
Extensive ply stiffening is now going on the deck mold. This is there to hold the mold in the correct shape
and to prevent any distortion that may create problems for the folding system alignment. This reinforcing has
to be done in just the right way, otherwise one runs the risk of the ply edges showing up on the finished deck
as 'print thru'. All these ply panels will next be laminated over, after which mold can be removed from plug.
Now we can show the stern - the finished boat may not actually look quite like what can be seen here,
but there's enough visible to give a general idea
Deck Mold Lamination Now Complete
November 20th 2012
All mold lamination is now complete and preparation is under way to fit the required timber stiffening. This
will then be laminated in place, which will probably take at least a week. Once complete the mold can be
lifted off the plug, and we will then finally be in a position to start making the first deck. Whitish strips
are pads that act as cushions under the timber stiffeners to prevent any 'print thru'.
Deck Mold Balsa Core
November 17th 2012
Seems like we are making it look worse! But a balsa core is being used to stiffen the deck mold, and this is
now cut and in place. More glass laminations will follow, and then the major timber reinforcing
Deck Mold Now Being Laminated
November 6th, 2012
Mold lamination begins, with the first layer of a light chopped strand mat (csm). Very important that this
The Deck Mold Process Begins
November 4th, 2012
Deck plug has now been sprayed with a black tooling gelcoat, after which the mold will be formed from
Deck Plug Almost Finished
October 26th, 3012
After weeks of fairing, sanding, and now polishing, the deck plug has progressed to where it is ready for
the deck mold to be made - our last major mold! Waxing should start next week, after which plug will be
sprayed with a tooling gelcoat, followed by the mold laminate (up to 12mm (1/2") thick. Mold will still
take at least two or three weeks to make, by the time all the reinforcing and wheels are in place, but we
should be making the first actual deck by the end of November.
The only significant mold left is the composite outboard bracket/well, which is now in process. Outboard
More Parts Completed
October 22nd, 2012
The first pop-top made and ready to fit
And the plug to make the mold for a 'mystery' part - can you guess what? It's a key item for the main hull
Deck Plug Almost Finished
October 14th, 2012
After much sanding, the deck plug is getting closer to where it can be polished, and the mold taken off.
Note the clean and well rounded bow - no clunky or corrosion prone metal fittings will be allowed on here.
The composite bow molding for forestay and bow pole which will fit inside is almost finished, and
while it has taken a while to develop and make, the clean and metal free bow will be well worth it.
First Assembled F-22 Leaves Factory!
September 29th, 2012
But not a production version yet! This was built from plans by local builder Rob Densem, and we had
helped Rob to put it together in our factory. But definitely a sign of things to come
Deck plug with its first coat of Duratec, and this is now in the final stages of finishing. It will next be
sanded flat, after which it will receive further coats of Duratec, the last one being relatively hard so
that it can be polished up to a high gloss. The mold can then be made!
Pop-top mold is now finished, and first pop-top is about to be made
The carbon wing mast mold now finished, but the above is all we can show. Construction of the first
mast will begin next week
Deck Plug Almost There!
Deposits To Be Accepted Soon
September 14th, 2012
finish coat of Duratec, after which the deck mold can be made. The foredeck hatch flat area has been formed,
as has the anchor well hatch recess, and also the pop-top area. This is being setup to allow either a pop-top or
a sliding hatch for those who prefer this option, but mono style sliding hatches do restrict the interior, and are
not necessary on a level sailing multihull. Stern and cockpit area have also been completed, but these will
have to remain under wraps for now.
Pop-top plug ready for the pop-top mold to be taken. It is longer fore and aft than earlier poptops, with a
Another piece almost complete, this being the anchor well.
the mold is made, which should happen over the next week. Section shown is the aft part of the wing (track area
is on top) and this mast is intended (all going well) to become the standard mast on both F-22 and F-22R. It will
also be available in kit form for F-22 home builders, and possibly for other designs.
Many aspects of the F-22 such as this are still being kept under wraps, so not much else can be said at present.
We are now getting close enough to where deposits will be accepted, and this will begin once the deck mold is
Our First F-22 Join Up!
Weight of the boat as shown is only 562kg (1236lb)
This is without rudder (8.7kg), daggerboard (12.2kg) and rig (approx 36kg), and is an excellent result.
Aug 14th, 2012
Only took a day and a half, and we should get this down to around 4 hours or so once our
crew get some more practice. And yes, those floats are just hanging there - the system is that
strong - no winches or control lines required. Not too many folding trimarans can do that.
Aug 14th, 2012
The basic pop-top mold shape is now established, and the first pop-top mold will be made from
Deck Plug and First Daggerboard
Aug 4th, 2012
Our first production daggerboard has just come out of the mold and it is perfect.
Thickness is consistent to ± 0.5mm, the best I have ever achieved for a molded board.
The same board can also be used in the centerboard version (with a few little changes).
Meanwhile, the deck plug is about to have the hatches formed
We are now assembling out first F-22! But before anyone gets too excited it is a local plan built boat,
and we are giving owner/builder Rob Densem a hand to put it together. This also gives the factory
crew a good look at how it all works, so many things can then start to make more sense, plus we will
have another boat to sail against when we launch our prototype.
Cockpit Floor Now Fitted
July 18th, 2012
Cockpit floor is now in place, and alloy rudder gudgeons are bolted on. Alloy with high performance PETP
plastic bushes (no slop) will be used for the base boat but carbon gudgeons will be used for the F-22R, once
development is complete. All models will however have carbon chainplates as standard. The floor will be
non-skidded later, once deck is on, as cockpit area is being done differently from all previous models.
DECK PLUG NOW FINISHED
July 12th, 2012
After much work, the deck plug is now complete and ready to lift off the form frames!
Lifting out - the cabin can be seen emerging underneath.
Now upright, trimmed, and about to go into our 'oven' overnight to thoroughly cure, so as to
INTERIOR FITOUT STARTS
July 5th, 2012
Forward bunk molding now in place, as are the Forward Beam Bulkheads. The actual 'real world' bunk width will be at the top of the cushion, or 100mm (4") above the bunk level shown. This is the roomiest bow bunk ever on any of my designs less than 28'.
The daggerboard case will go in next, followed by cockpit floor and Aft Beam Bulkheads, and then hull will be finished and waiting for the first deck. In this regard the deck plug is now basically finished, and we are currently adding the necessary reinforcement underneath, to where it can be removed from form frames. The final surface finishing can thus start next week, and then the actual deck mold can be made. This will probably take another four to six weeks after which we can finally finish our first boat. Everything just takes time with developing a completely new model, and we may start to build some more hulls while we wait, to help speed up the first deliveries.
First Deck Photo!
June 22nd, 2012
We have been working on the F-22 deck plug for some time, as there have been quite a few new developments in this area, plus we had to disassemble and then reassemble again when moving factories. But we are almost there, and finally have a photo that can be shown:
This is the underside of the deck plug and the glossy finished surface will be on other side, from which
The original F-31 deck mold (as setup for the previous second generation folding system). This is better with
We Have Lift Out!
May 18th, 2012
First F-22 main hull just lifted out of the mold, and it is perfect
Main hull now trimmed and ready for the deck
Interior Starting to Go Together
May 5th, 2012
The main internal molds (Forward Bunk and Cockpit Floor) are now complete, with just three small
Beam bulkheads, ready to fit into main hull once Forward bunk and Cockpit Floor are fitted. The opening
March 31st, 2012
Gelcoat booth ready to go - just the floor liner to go in - it's big enough to put a truck in
March 24th, 2012
New Gelcoat booth being painted, and this will be finished on Monday. Just the explosion proof lights
Cockpit floor plug in place in the first hull, ready for the mold to be taken off. This same mold will then
March 18th, 2012
fan ducting going up to the roof. We get quite a gale going through the trim booth, which really makes
trimming almost a pleasure - the dust gets whipped away before it can get near you. The lights are still to
go in, with painting to be done, but another week and we should be able to gelcoat big parts once more.
Otherwise the main hull interior molds are still in progress, as is the deck plug, but the production F-22
February 18th, 2012
We are now in, and do not know how all our gear and equipment fitted into the old factory! However, plenty of
New gelcoat and trim booths are being built, with the air into the gelcoat booth being properly filtered and heated
Plenty of room for expansion outside as well. Trim booth fan ducting can be seen at left - fan is very powerful
Beginning The Move!
January 29th, 2012
The move into our new much larger factory has started, with the 'first in' main hull mold shown above. We
were having to squeeze by this in the old factory, but now there's plenty of room! Downside is the move
logistics and setting up the new factory with gelcoat and trim booths etc. will take some time, and interrupt
progress. But we will at least now have plenty of room to start production once ready.
Container at our old factory, packed full of assorted molds and other equipment, ready to be moved.
Two of the main hull interior molds made, and ready to remove once the move is complete.
Main Hull Interior
December 19th, 2011
Main hull with forward bunk and cockpit floor panels in place, and almost ready to make the first
The forward bunk is 1.3m (4' 3") wide at shoulder level, and 0.65m (2' 2") wide at foot level for those
The forward part of the completed deck gunwale flange can just be seen at right (against wall) waiting
Deck Join Flange Under Construction
November 27th, 2011
With the first main hull made, attention has now moved to the deck plug, from which the deck mold
will be made. Photo shows the CNC machined deck or gunwale flange plug ready to laminate, which
is being done as a separate item with the F-22. This is because it has a number of new aspects that require
an exact fit on the hull. Doing it this way means we can check the fit on the hull, and get it just right before
the flange is added to the full deck plug, which is being built separately.
First Main Hull Now Made
November 10th, 2011
Foam core and fiberglass fabric being fitted in place
Vacuum bagged and ready to resin infuse
Fully infused with resin - hull now made. The first infusion is always a little hard on the nerves,
I'm sure all home builders will be impressed at how fast we can now build a hull, just over a week for
Main Hull Mold Preparation Work Now Complete
18th October, 2011
Main hull mold now set up to rotate, which is essential for easy gelcoat application and then infusion.
The mold weighs around a ton, so pivot points have to be super strong.
First production main hull now gelcoated, lamination about to begin.
Another key part of the equipment required are gantry cranes so that hull can be lifted out of mold.
Another piece of the puzzle now complete - the daggerboard molds.
Main Hull Mold Arrives At Our Factory
8th September, 2011
Mold now inside our secondary assembly area, and taking up a large amount of space. Next major step
Our just made extra large laminating/infusion table for making flat foam core panels. These will be used for
It Had To Go!
30th August, 2011
to clear the decks for the deck plug and mold. Teeth were well gritted before the first cut, but it had to be
done. Being made from MDF it would not have lasted long, due to weather related movement, which means
it would have lost the fine finish. A fully stable fiberglass plug will be made out of the first mold once it has
been conditioned, and this will then be used to make more hull molds when required.
How it was before:
The original F-27 hull mold plug, but in this case an actual foam/glass main hull was built, which then
The hull mold now polished, waxed, and ready to go!
We Have Lift Off!
10th August, 2011
Main hull mold just removed from the plug (behind)
and rolling it upright
Making The Main Hull Mold
21st July, 2011
Multiple layers of glass are now being applied over the plug (shown below) to make the mold. Just a few more
Main Hull Plug Ready For Making the Mold!
11th July, 2011
Not long now!
The main hull will have a conventional deck to hull gunwale join, as this still works best for wingnet
The continuing Christchurch earthquakes have slowed things a little the past month or so, but with
Farrier Marine's Annual Day Out - next year we hope to have it on the harbour! The liquefaction in
We are also doing numerous tests to determine the best possible laminate and material combination for the
Daggerboard Plugs Arrive
14th June, 2011
Fresh from the CNC shop
Main Hull Plug Getting Close
June 6th, 2011
Now at final fairing coat stage - almost ready for the gloss coat, and then only some polishing left to do!
Just One More Bit To Go!
May 16th, 2011
Two floats, 4 beams, a folding system, daggerboard case, and rudder, all waiting for the main hull,
which will not be far away
The Main Hull Plug
May 12th, 2011
The main hull plug now almost complete, having been assembled from CNC cut sections. This is possibly the
Stern area, with folding system recessess visible
Main hull bow is very fine for slicing through waves
The special float hatch deck trim now in place and ready to fit hatch. Float hatches have always been a
Some earthquake damage at the mold maker's factory, on the wall and floor - now there's just that little bit
March 22nd, 2011
Now There Are Two Floats
The second F-22 float has now been completed, so now we have the floats, beams, folding system, rudder,
and daggerboard case, with just the main hull to go. Floats are still not quite ready for full production, with
a few more procedure improvements still to be implemented, but they are now close enough to where we
can move our main focus onto building the main hull!
February 17th, 2011
First Production Float Now Joined
The first two float halves have now been joined, photos below:
Shape is now clearly visible and those familiar with my earlier designs will note that there are only two hatches (used to be 4 - 5). This is because hatches have always been a source of annoying problems with leaks etc., so minimizing these is a major advance. The new joining system eliminated the need for access to the float interior, as the unique joining process does not require it, and the only need for hatches now is to access the beam bolts and middle storage compartment, for which two hatches are enough.
Float is still divided into three large watertight compartments, and to ensure each compartment can be drained, and vented, a new venting system has been developed. Good float venting has been much more important than realized earlier, as we now believe lack of sufficient venting can lead to badly leaking hatches when sailing hard through waves. These can cause the float to pant, and act like a big pump, to push air out and suck water in through even the smallest gap or weak hatch seals. The F-22 venting system has a much greater capacity (over 1000% more area) than earlier float venting systems for this reason. So half the hatches, and no pumping action, means a much greater chance of having 100% leak proof floats
Finished float decks will be very clean, and with few metal parts.
Carbon chainplate is shown - these have always been used on plan or home built F-22s, but it was uncertain if they could be incorporated on a production float, as it is not easy to make the chainplates in a production environment, and then fit in a molded hull. However, all the problems have been solved, with chainplates being full infused in one piece, and they are actually easier to install than metal chainplates. All heavy stainless has thus been eliminated, with the chainplate becoming part of the laminate/hull, which eliminates any chance of metal corrosion or leaks. One could dig 3mm deep into the hull around the chainplate edge, and it would still not leak!
Photo shows a clear coat finish chainplate, mainly because we could do it, but the standard production chainplate will have a white gelcoat finish, and the clear coat version may be an option.
Another finished float view, with the next float half in front, having just been resin infused.
Having a clean floor makes it very easy to make up the vacuum bag for the next float half!
January 28th, 2011
First Production Float Halves Complete
A few more floats to make, and we will then be ready for the main hull mold to arrive, and we can start making the first main hull. Quite a lot of work still to be done, with more jigs and fixtures etc., but it is starting to get much more interesting.
Final float half being lifted out of the mold
Being turned over - very light and easy for just two to handle
The two finished float halves, ready for trimming, after which they can be joined.
Two hours later, with halves now trimmed, and first trial fit. Join seam is just about perfect and will
December 22nd, 2010
First Production Float Half Infusion
Infusion just started - resin can be seen entering the hull/bow area at right.
and the finished infused hull - laminate is perfect with zero voids.
One of the Distractions:
It has been important for the F-22 to be self-financing, to ensure viability and maintain design integrity, so
December 21st, 2010
First Actual Production Float Now Being Made
The trials and tests are over, with the necessary assembly jigs now made, and the first actual production
float is being made today. Above photo shows the first exterior layers of glass, plus foam core deck in place.
Every little detail is being checked, double checked, and then refined even more. This is to ensure the best
possible float that is strong, as well as both easy to make and as light as possible.
December 8th, 2010
Second Float Half Also Removed From Mold
The now trimmed original test skinout - cannot be used as a hull, so will now be have to be
cut up (with gritted teeth) and thrown away....ouch!
December 6th, 2010
Now Removed From Mold
Fresh out of the mold and still untrimmed
Second Float Half Skinout Also Now Infused!
.....went even faster!
December 2nd, 2010
December 2nd, 2010
First Float Half Skinout Ready For Trial Infusion
F-22 Float Mold Lamination
November 30th, 2010
First float half gelcoated and having initial conditioning skinout - one of the few things that we hand
laminate. Next step will be to infuse a trial laminate on this, in order to get the resin flow just right
F-22 Float Molds Now Made And Ready For Gelcoating
Onn wheels, fully waxed, and ready to go make hulls