With a computer controlled cutter, the particleboard ‘stations’ are cut out and assembled on the floor on a temporary foundation made of framing lumber to form an upside down boat. Full-length strips of fir are fastened to the particleboard along the length of the boat. This mold is very carefully built to be sure that the boat will be “fair” (one long, sweeping curve, not lots of little bumps).
On top of this mold, a large sheet of plastic is placed with covers the entire boat. The plastic sheet serves as the inner part of the “vacuum bag” process – a process of epoxying together several layers of material with suction to form a tight bond.
Today, the facility at Schooner Creek houses a full-service boatyard and boat building operation, including a metal fabrication shop, wood shop, full rigging loft, travel lift capacity up to 70 tons, an indoor paint booth, a dry dock, and enough space to construct, service and store dozens of vessels indoor and out.
Schooner Creek has also invested in the StormwateRx water reclamation system to ensure that all rainwater washoff is treated to remove any contaminants before it is returned to the environment.