Mold Making Process

If you read last week’s V Report, you gained insight into the plug cutting process we do in-house. Now we’ll show you the plugs moving to the R&D floor where our specialists begin the mold making process. Above is the V-29 Hybrid hull plug nearing completion of the finish cut.

The process consists of multiple phases involving different types of materials, areas of expertise and teamwork. Once the plug is done cutting, three coats of primer are applied. Any part that needs nonskid gets sprayed during this stage. The final coat is waxed five times before the tooling gelcoat is applied. Above: The V-28 Bay boat is getting sanded between the second and third coats of primer.

The (orange) tooling gelcoat is applied in two coats to ensure proper coverage and thickness; seen to the left is the V-29 hull plug. Once it is cured, our fiberglass specialists will begin laying material. Over six layers of fiberglass and resin are applied. Afterwards, the eggcrate is assembled; an “exoskeleton” framed in double 3/4 inch plywood that is also fiberglassed for extra strength and durability. Finally, a steel framework is added to ensure the rigidity and longevity of the mold. On the right, is the V-29 getting its layers of fiberglass applied while the V-28 in the background has its eggcrate installed. 

Now that the mold is complete, our boat builders will separate the plug from the mold and begin the final phase. Consisting of hand fairing, sanding, waxing and buffing the perfect finish is achieved and the mold is ready to move to the production line at the Mullica facility. Above the V-29 hull mold is being separated by overhead bridge cranes.

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