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| FUSION
40 - Moulded
Sections and Construction Pictures |
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Construction
Flexibilty
By producing this modern catamaran
in modules, which in turn fit in containers,
it has meant delivery throughout Australia is
simple and it has opened the doors to worldwide
marketing of the Fusion
40. The cost savings on overseas
shipping is in excess of $40,000.00.
By producing a catamaran in
sections also has great appeal to the professional
boatbuilder as well as amateurs, as they can
install mechanical and furniture items as they
assemble, rather than working in confined spaces.
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GELCOATING:
The 10 metre by 14 metre spray booth is fully ducted and Gelcoat is applied
using the latest "Robinson" gel spray system. The foreward
underwater section can be seen being sprayed.
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LAYUP:
One of the benefits of a dry layup for Infusion moulding is that each layup
can be individual, depending on the crafts end use. Optional layups
are available, such as Kevlar. |
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The
infusion moulded underwater section is lifted
from its mould. This section unlike most other
production Catamarans is long and lean, giving
the Fusion 40 a definite performance advantage. |
These hulls have been primed, ready for antifoul, as this one is being
produced as a motoraway for a Southern Client. Note the lack of mini
keels as this owner opted to build his own centreboards.
STEP
1
The Hulls are now ready for placement in the Jig.
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STEP
2:
The inner port hull/chamfer panel is positioned on the underwater section.
These 2 overlaps
are adhered and also glass taped on
the waterline. A 2mm fairing joggle
has been allowed for the boot-top fairing.
Having a seperate bow section allows
for easy fitting of the forebeam, whether
it be Aluminium or composite.
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Underwater hulls and Port Chamfer sit in the
specially constructed laser alignment jig. The
tolerance within the jig is less than half a
mm over 12 metres. This Jig is used to pre-align
the Kits before they are disassembled and containerised. |
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STEP
3:
Place the Starboard Inside Hull/Chamfer on the Stbd Underwater section.
With the four components
in place, the structure is readied for the
Bridgedeck moulding.
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STEP
4:
Fit the bridgedeck.
The large bridgedeck
section is lifted and . . .
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placed into
position where the pin holes are aligned |
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the 5 lower sections are in place, we can move
to the aft end which starts bringing your Fusion
40 to life. |
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The aft beam
is moulded in two sections (inner and outer).
The inner section will have the cockpit seating
as part of the mould |
STEP
5:
Position the Aft Beam.
In this picture,
the aft beam has had the steering access
hatches cut out and is now in position
where it joins the Underwater Hulls,
Chamfer Panels and the Bridgedeck.
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The extra wide
steps have been designed to give the best possible
access, whether from the dinghy or the dock and
naturally have the non slip already moulded in. |
STEP
6:
Position the Steps.
With the steps in place
the enormous volume of the Fusion 40 becomes
apparent.
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At
this stage of the construction, you would carry
out tank, steering, engine and rudder installation,
and when the full bulkheads are in you can start
on the interior fitout. This vessel has been
designed to be constructed similar to large production
catamaran companies, allowing full and easy access
to all areas. |
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STEP
7:
Position the Cockpit.
With the Port
and Starboard Cockpit moulds together,
the beautiful flowing lines of the
Fusion can be seen |
STEP
8:
The Main Companionway Bulkhead is installed
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These
pictures of the cockpit unfortunately do not
show the beautiful flowing lines and the well
designed functionality of the Fusion 40s Cockpit |
STEP
9:
The Port Hull Side and Deck is the next component to be installed. |
The 3 sections of the Saloon Roof and foredeck are positioned and joined
prior to being erected on the already assembled hull and deck. |
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This picture
shows 2 of the roof sections in place and the
nose cone attached.
STEP 10:
The completed roof section is lifted and adhered in position. |
When all the components
are assembled and adhered, the small seam at
the join line is faired.
The product that has
been recommended is Fixseal MSP15. It is
a high quality single-component flexible
adhesive joint sealant, suitable for above
and below waterline applications. Based on
MS-Polymer, chemically neutral and fully
elastic. Suitable for use in low movement
joints in marine, automotive, aerospace and
construction applications where a tough flexible
adhesive sealant is required.
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Fairing
the join:
Each part is manufactured with a negative or positive joggle. The two parts
here have been positioned with an overlap and the Plexus Fusion adhesive
applied.
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Once the adhesive
is cured, 1 to 2 hours, the MSP15 filler can
be applied |
For
a nice smooth finish, it is recommended that
a detergent be sprayed onto the surface after
the MSP15 filler has been applied.
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Then using
a plastic or metal implement you simply wipe
away the excess.
This gives an almost
invisible finish to your plexus join.
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This
web page will grow with the Fusion Project, so
visit me again soon.
If
you are a Professional Boatbuilder or
a Home Builder and you would like any
further information on these project
boats, please contact me at jim@multihullsales.com or Phone
+61 7 49464659
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