This is how a Landmark 43 is built...

Transcription

1 This is how a Landmark 43 is built... Landmark yachts are built by Premier Composite Technologies in Dubai. The Landmark 43 is built using the latest composite technology. The hull and most parts are made in a sandwich construction with foam core, E-Glass and Epoxy by a vacuum infusion process. The keel construction is made of aluminum which is bolted to the inner line of the boat. Scroll down to see the build process of Landmark 43 hull no 9 during a period of 5 months: Update March 7th 2011: The inner liner is trimmed and prepared to be glued/laminated to the hull. The deck mould is prepared for laminating. New window inlays large enough to accommodate Lewmar flush portholes are installed in the mould.

2 PCT made an engine bed in epoxy with built-in aluminum engine bracket supports. Less than 50 % of the weight of the original Volvo supplied engine bed! The hull is sitting in the "blue jig" during liner and deck assembly. Markus Mehlen, Project Manager at Premier, oversees the vacuum infused lightweight bulkheads which are ready to be glassed in. Gel coat sprayed on gloss parts only. Grey non skid epoxy paint will be sprayed after deck assembly.

3 Plug for the new keel fin with IRC accepted cutouts for weight reduction. Weight saving approximately kg. The keel construction that carries the keel is made of aluminium which is bolted to the innerline of the boat. The Keel is bolted both to the hull and the aluminium frame. To prevent cracks, the frame is not laminated to the hull Update March 8th 2011: The hull is ready to receive the inner lining. Preparations for the rudder base, engine base and keel mount have been made. Working on the deck that still sits in the mold. Ceilings are sanded to get spray painted afterwards.

4 Work is done in parallel on the different parts of the boat. While working on the deck, another team is working on the hull (below). Preparing to lower the structural lining which will provide strength/stiffness to the hull and act as a platform for all the furniture. The lining floats over the workers' heads. All parts a prefabricated and waiting to be installed. This picture shows some of the bulkheads, all made out of sandwich constructions. All furniture is ready (not shown) and as soon as the lining is bonded to the hull, furniture will be placed. The keel bulb and fin are at the foundry, the rudder is almost finished. Update March 24th 2011:

5 All major bulkheads have been installed. Blue tape has been applied to prevend damage. In the middle you can clearly see the bracket onto which the motor will be installed. The inner side of the bow. Peelply has not been removed yet, only partly. The bottom of the anchor locker is tilted forward so that water will easily find it's way to the two drainholes. Looking from the bow inside, standing in the front cabin.

6 Toilet area. Sink and cubboard door to be installed. Looking from the main cabin forward. On the right the cubboard for wet cloths. The inner lining has now been completely fixed onto the hull. Some compartiments of the inner lining have been closed completely to prevend water coming in. These sections can be used for storage as well.

7 Chart table base with an inspection hatch. On the right side of the picture: the L- shape is the base for the kitchen block. Part of the kitchen base. Kitchen base.

8 One of the aft bulkheads. The openings enable you to reach the rudder shaft and hydraulics. The deck, upside down, has now been lifted from the mold. Work in progress. Ceilings have been sanded and spray painted. The opening is actually the entrance of the gas bin. Bulkhead that supports the aft deck. One can see the edge of the stern. You can clearly see that the bulkheads are laminated on to the hull.

9 The doors for the two lockers in the aft cockpit floor. They will receive teak on top before being mounted with hinges. Update March 29th The build team is painting the inner hull. Main cabin All bulkheads installed in the mid section aft. The large locker sitting in the front, right.

10 Main cabin bunk on port side. Engine bed. Time to install the engine! First pieces of furniture installed: the chart table and the cubboard behind the chart table. Nicely wrapped to prevent damage and I suspect workers will do some spray paint jobs as well later on. Fitting out the small cubboards in the main cabin. Masterpiece from Claus himself. I would say they need some white paint ;-)

11 Helicopter view of the toilet. Looking down into the cubboard. Workers keep everything very tidy, good show. Chart table on it's pedestral. Another masterpiece from Claus on the starboard side!

12 Inner hull nicely painted in white. Work in progress on the deck (upside down. Workers are fitting some pieces below deck that carry blocks for bringing around some of the lines. This piece is glued onto the hull using vacuum techniques. Looking from the main cabin forward. Forward cabin with the tube of the bowsprit going right through.

13 Front cabin with lower cubboard installed. Bowsprit tube end - taken from the toilet. This is where the a turning block will be installed for retracting the pole. Fitting aft in the hull: this fitting will receive the hydraulic cylinder for the backstay. Toilet cubboard waiting to receive a sink and door.

14 Bow section: the plate on which the forestay (furler) is mounted is now laminated onto the hull. The bowsprit tube fitted in the bow section going through two bulkheads with an additional reinforcement laminated onto the hull. Update April 15th The hull is getting ready as the main components have been installed like furniture, engine and inner lining components. Soon the deck and stern will be mounted onto the hull. The deck is waiting for the upper bearings for the rudderstock. Chart table, panels for electronics and cubboard now installed.

15 Kitchen block completely installed. Engine is now installed and covered in plastic. Working on the water supply and drains under the kitchen sink. The aluminum keel structure has been glued and bolted onto the inner lining of the boat. Front part of the structure onto which the mast will be stepped. First a cover plate will be bolted onto the structure.

16 Sink installed in the toilet area. Cubboards in the front cabin. Wiring up the boat. Isotherm heating unit which is situated right beneath the cockpit floor. The diesel line will only be fitted when the boat is almost finished because it is a vulnarable tube. In the back aft the 8mm copper tube for the gas bin connecting to the stove. In the process of fairing the bowsprit tube.

17 Back of the port- sideway of the cockpit: getting appliances installed. This is the deck shower and an air inlet. Stern getting ready to be installed. Main cabin steps just out of the mold. It will receive teak steps later on. Handy cubboard at the top end; this is a modification to the first models. Update May 2nd The deck has been mounted on the hull and the building process has come to it's final stage. Another 2-3 weeks to complete the boat from here.

18 The keel bulb with composite skin, faired and spray painted, ready to be mounted to the keel fin. Torpedo shape with a flat fin for more stability and lift. Weight around 3000 kg of lead. The keel fin will be mounted in this slot.

19 The cradle will be used to transport the boat. The cradle can be adjusted in height to accommodate for the hull with the keel mounted. The two blue poles are the pedestrals on which both steering wheels will be mounted. The pedestrals are made out of carbon composite and specifically made for the Landmark 43. Next to the pedestrals the footrests for the mainsheet trimmer with cam cleats to lock the traveller line. The locker for the gas bottle in the cockpit received it's door. Inside of the locker with the gas tube waiting to be hooked up.

20 The Claus special; additional lockers in the main cabin now mounted on either side and waiting to receive the hinched fineer doors. As the deck is mounted the ceilings get installed. This is the ceiling in the aft cabin at the port side. One can also see two tubes in the upper right corner: these tubes have running rigging inside. Mainsheet and spinnaker barber hauler. The side window in the main cabin. This is a deviation from the original design as the original design did not have a port hole installed that can be opened. Latest model Lewmar porthole will fit in the middle section. The mast collar is integrated in the deck with holes for mounting the halyard turning blocks and eyepads.

21 The bow received the forward pulpit with holders to receive the carbon bow lights. The tube rails and composite foldable anchor roller still to be installed. Stanchions installed on the deck. The stanchions at the cockpit section have additional support to be able to carry the weight of the crew when hanging overboard during close reaching. Cut out for one of the foldable mooring cleats. Update May 16th

22 The team is sanding and polishing the hull and deck. The blue pieces of tape indicate irregularities in the gelcoat that need further attention. Four workers sanding and polishing.

23 more sanding.. And after two days the hull is completely sanded and polished. That's how we do that in Dubai! The team has been sanding and polishing the hull and deck for about a week now.

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25 The stern received a specially made carbon block that will guide the dyneema backstay into the hull, connecting to the hydraulic cylinder.

26 Temperature in Dubai this time a year is around 42 degrees Celcius in the shadow. Premier cools it's facilities to make sure that composites do not cure to fast. At the same time an airco unit provides cool air to the workers inside the boat. The anchor locker opened. The foldable anchor roller is prefitted (and not visible) and lands in the holes in the front of the boat. Work is progressing both inside and outside the hull How many workers can we fit in a boat?

27 Fixing the ceilings in the main cabin. And smiling! The carbon rudder stock is ready to receive the quadrant and the rudder blade. The rudder blade comes in two halves and will be laminated to the stock. The companion way ready to receive the hatch and teak frame. Care has been taken to drain water from beneath the hatch. Special groves (water trap) in the hatch prevent water from dripping in the cabin. Water will flow into the cockpit. From a distance the window should look like one big window. The lewmar porthole will fit right in between.

28 After the sanding the deck will receive another layer of grey paint. After that the deck gear will be mounted. All deck gear has been prefitted and holes are prepared and strengthened with epoxy and spabond. Hydraulic pump mounted under the cockpit. The two carbon steering pedestrals covered in paper. Hole for the rudder stock. One can clearly see the reinforcement of the deck in this area. This is where the lower rudder bearing will be mounted. It's housing will be laminated on to the hull. Reinforcement bar for the winch.

29 Lightweight anchor chain box. The anchor winch will be mounted on top. By removing three bolts, the box can be removed to further save weight during regatta's. Update May 25th The optional lockers in the main cabin received their lightweight doors. All lights in the ceilings are LED lights with a nice extra feature: during night time they can be switched to red LED light. The sidewalls receive the covers. The covers are made of lightweight composite material covered by light grey cloth.

30 The electric panel installed. 28 switches, enough to cover all appliances plus a number of spare switches. A digital meter shows voltage and current of the battery banks. Wiring on it's way. All wires are coded as one can expect. The 230 Volt circuit breaker is situated in the starboard locker in the aft cabin The electric hallyard winch situated at the port side with thick leads connected to the relay.

31 Circuit breaker in a nice enclosure. This is no standard stuff but specifically made by PCT for this purpose. The heads nearing it's completion. The bowsprit tube received a cover plate and will soon be covered by a large mirror. A wire to connect a mirror light at a later stage. In the sink cubboard the flush sea cock nicely hidden under a lightweight panel, easily reachable. Modification: an extra large hatch in the left kitchen sink cubboard. This extra space can be utilised for large pots or bottles.

32 Aft cabin side wall waiting to receive the panels, to be attached with velcro. Same for the ceiling panels. The deck received all of it's Harken winches and Spinlock clutches. Large clutches for the spi hallyards and the genua hallyard. The downhaul and cunningham are led through camcleats on either side of the hatch. Retractable composite anchor roller mounted. Note the hinched panel in the hatch; this can be opened while the anchor roller is on the deck. Nice detailing: one of the six recessed mooring cleats.

33 Modification to the original design: a second folding padeye on the foredeck to accomodate a stay sail. Gear for the spinnaker guys. The hull received it's blue waterline striping and a layer of coating. It's looking great.

34 Nice detail at the bow: carbon fiber cover for the anchor locker drainholes. Work in progress: the lightweight composite quadrant, made by PCT themselves, waiting to receive the rudder stock- and blades. Update June 2nd 2011 Two weeks before completion. The yard is installing the last components and finishing the interior. The heads is finished. The bowsprit tube end is nicely covered by a large mirror.

35 The electric toilet installed with the operating buttons nicely installed in front of you.. Last teak door frames being fitted. Next are the lightweight, foam cored doors. Does your boat have teak frames around the hatches? Wel mine has!

36 All cubboards finished and the blue cushions arrived as well. The aluminum pipecot installed in the aft cabins. Handy for storing luggage or, if you really want, you can sleep in them. The cam cleat near the steering wheel will handle the main traveller line. The traveller rail installed on the aft deck. Slightly tilted in the direction of the mainsheet attaching to the boom.

37 With the blue striping the bow is looking magnificent. Navigation lights checked! Update June 8th 2011 Hull #9 is finished! Completely finished interior with the lightweight floorboards installed. The floorboards have a non-slippery formica surface in a dark wooden finish and they are fixed to the inner lining by means of velcro. The table stand with the table installed. The table can be easily lifted from the table stand and stored on shore during racing. The staircase with teak steps. The steps have a awlgrip finish that prevents you sliding your way in. You can see the handy storage area under the top step. Ideal for storing winches and other deckgear.

38 With the additional 4 cubboards there is plenty of storage in the main cabin. Refrigiator unit in the toploading fridge. A nice teak piece in the heads. Underneath is the drain for the shower with a showerpump installed in the sink cubboard.

39 Shower pump and drains mounted in the cubboard. Bottom hatches can be lifted to inspect the hull. Does your boat have carbon doorsteps? Mine has... The shutters for different water drains. These Marelon shutters have completely leveled skin closure on the outside of the hull, and therefore no resistance while closed. The kitchen valve sits right behind the keel and can therefore stay open during racing.

40 Chart table ready to navigate. The hinched console for the computer screen will mounted later. All wiring neatly hidden behind the nav table hinched panel. Manual bilge pump with large capacity in the aft starboard cabin. The Landmark comes standard with two manual pumps. Diesel, water and black water filler caps hidden in the main locker in the cockpit. Do not make a mistake here.

41 First sighting of the rudder: completely build from carbon composite. Weight: 25 kilograms (!!!!) Ceiling around the mast in the main cabin. Another masterpiece of the yard: this all carbon turning block sits on the stern of the boat and guides the dyneema backstay down to the hydraulic cylinder inside the hull.

42 On request the yard made two opening hatches (portholes) in the main cabin. On each side a Lewmar hatch is installed halfway in the large window. Finished with a carbon frame. Excellent finishing touch. And this is how it looks from the outside. The porthole is hardly noticable because of the all dark materials.

43 A total of 6 clutches on each side. Camcleats for boomvang and main outhaul. Mast base with halyard blocks and padeyes. The foldable padeyes are there to snap halyards that are not in use during sailing. And last but not least: the entrance for the forestay going to the furler underdeck. This entrance will be covered by a carbon frame. Aft pulpit. Turning block for the spinnaker sheet will be attached to the eye on the bottom right.

44 Gas bin large enough to fit a lightweight composite gas bottle. The door carries the handle for the mergency manual bilge pump in the cockpit. All the water drains under the cockpit end up in the main drainage tube. The hydraulics panel right next to the starboard pedestral / steering wheel. The mainsheet trimmer is able to trim the dyneema backstay with the push of a button. If there is a power failure on-board, then the system can be operated manually. For hull #9 we have specifically requested to move the throttle handle forward. Dangerous anyway to keep it in the recess because it can be caught in the mainsheet during a gibe. The open space will be filled up with the B&G plotter and pilot display.

45 And here we are. After 5 months of hard work the Landmark 43 is finished. Next she will be covered in shrink wrapped plastic and transported to Holland. Update June 13th 2011 Shrink wrapping the boat and getting ready for transport to Jebel Ali - port of Dubai With the hull strapped on the cradle, the team is covering the boat with shrinkable plastic. Webbing to make sure that water will not be trapped on the boat during sea transport.

46 By heat the plastic is tightened around the hull. Update June 18th 2011 Preparing the keel fin The raw casted keelfin with fresh cut recesses 10 mm deep on both sides to save weight. The recesses are filled up with epoxy filler and the front of the fin received it's final shape with epoxy filler as well.

47 Tapping the holes at the top end of the fin. Yes, 90 degrees straight up works best. Fairing the keelfin. The shape is checked at several positions with different templates.

48 Top end received the screw heads. Finished with epoxy primer and fitted on the boat. Ready for the tedious job of positiong the fin exactly under 90 degrees under the hull. Like a razor.. This fin is actually a lot wider than the deep keel fin. Total draft is 2.50 mtr for hull #9 instead of 2.70 mtr for a standard Landmark 43. Eventhough hull #9 will carry the same sail area as for a standard LM43.

49 Fairing the keel fin attachment while mounted under the hull Complete keel with bulb mounted getting last epoxy primer sprayed on. Total weight: little over 4000 kg. The shrink wrapped hull with cradle to be loaded on to the flat rack (a container sized platform). Strapping down the 4 ton keel.

50 Ready to be transported to Jebel Ali port! The team gave her a final blessing!

51 The team at Premier Composites in Dubai that made it happen with project leader Markus Mehlen sitting in front left. Well done! Thank you. Update HallSpars June 23rd 2011 HallSpars finished the construction of the carbon composite mast and assembly is underway. Busy fixing the track for the main sail. Brackets for the B&G console with the (5) displays, and the boom and boomvang attachments. Foldable footstep mounted on the side.

52 Top end of the mast. The aluminum piece is the windex with a light mounted underneath. The wind meter will fit into the carbon tube at the bottom.