Valhalla 55 Sport

The tooling phase for the construction of our new Valhalla 55 Sport is moving along swiftly. The new outboard-powered high-performance cruising yacht will utilize the proven hull of our V-55 center console but feature an entirely new look from the waterline up.

What started as a mammoth foam mass begins to take the shape of the 55’s deck. Our 5-axis CNC router has carved away the bulk of the foam to create an offset surface of the actual shape, including the coaming, asymmetrical sidedecks, cockpit sole and aft seating backrest module. The CNC room has the interior volume to accommodate a hull or part up to 60 feet long. Plugs for larger models are made of several sections that are pieced and bonded together in the R&D Department.

After the completion of the first phase – called the “rough cut” – an epoxy paste is applied via a specialized metering, mixing and dispensing machine to the entire surface of the foam. 

With the epoxy cured, the 5-axis is back in action, sculpting the structure into its final shape. In this view you can see the yacht’s port and starboard boarding platforms that extend aft of the transom. It takes just under two weeks – which includes around-the-clock cutting – to complete the tooling stages inside the 5-axis room for a part of this size.

The same procedure is carried out for the console, which will be joined with the deck liner to become one large plug. The plug will then be used to create a mold, which will then be utilized to build the actual fiberglass part.

The R&D team uses overhead hoists to guide the console onto the deck liner.

The team finishes fitting the console inside the deck.

Meanwhile, the rough cut of the 55 Sport’s pilothouse is taking place.

The final cut shows the intricate lines and recessed areas of the part, which include the windshield, side windows and hardtop.

Stay tuned for more as we follow the build of our newest Valhalla.

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