2026 Archive : Northstar Orion 8 Boat Cover

Project Details

Fabric 1

Neptune Acrylic Canvas
Producer/Manufacturer: Ricky Richards (Sales) Pty Ltd.
Primary Use: Main Fabric

Design Name
Ki-Raphael Sulkowski

Design Company
K1 Marine Trimming Pty Ltd

Fabrication Name
Ki-Raphael Sulkowski

Fabrication Company
K1 Marine Trimming Pty Ltd

Project Manager Name
Ki-Raphael Sulkowski

Project Manager Company
K1 Marine Trimming Pty Ltd

Installation Name
Ki-Raphael Sulkowski

Installation Company
K1 Marine Trimming Pty Ltd

Please describe the project specifications

The client requested a full boat cover for his Orion Northstar, saying he had covers in the past that were heavy/ cumbersome, and difficult install/remove, were poorly fitting, and wearing through. He also wanted the cover to be as easy as possible to take off and on.

We designed the cover to go over the whole boat, over the t top and outboard engine, as well as down to the trailer in order to prevent damage from rocks/debris when driving the boat around. Given the size of the boat we opted for a two piece design, (forward and aft) which allows for easy installation in two sections. The location of the zip that joins the two pieces makes it easy for the client to access the boat when the cover is on, as well as providing safe and convenient access when joining the pieces as the cover goes on.

We reinforced the high wear areas, such as the T Top and the outboard motor, with abrasive resistant materials to prevent foreseeable wear to the cover. We used a streamlined bungee cord and clip method to secure the cover to the trailer, allowing the client to easily secure and release the cover. We patterned the cover for an exceptional fit to minimise the wear and tear impacts of fabric stress during heavy weather or while towing which can distort/ damage the cover. The result is a very visually appealing but also functional boat cover that meets the clients brief in every aspect.
We see this cover as being unique in its execution given the large size of the boat and the precision finish of the cover.

There were several key challenges associated with the size (height and length) of the boat as the cover was to go over the top of the T Top:
• Patterning: Careful consideration and planning from a manual handling/ safety perspective remained a key consideration of the patterning process due to the physical demands of reaching/ accessing the areas required to safely pattern the boat. In addition, the pattern fabric needed to be prepared and sewn together in the workshop beforehand, to ensure the pieces were big enough to cover the boat. This was in order to maximise productivity/ avoid costly delays of not having wide enough pieces of pattern fabric to cover the vessel, and trying to join the pattern fabric onsite (which is difficult to do accurately in any significant length).
• Order of manufacturing: The large size of the pattern pieces required us to carefully plan out the order of sewing for each of the panels to ensure the large amount of fabric would fit under the arm of the sewing machine. Taking the time to plan this out properly in the beginning avoided preventable delays and complications when it came time to sew the project together, and meant we could maximise the efficiency of the workshop/ manufacturing process. Ie. this project could be completed efficiently in the time that had been quoted, as well as not obstructing the completion of other projects both physically (due to the size of the panels) as well as flow on scheduling impacts.
• The design and location of the zip join and weather flap behind the T Top required careful planning regarding its position on the cover to enable access to the boat, and optimise usability (ease of joining the front and back pieces) without compromising the taut fit of the cover or the water leak/ weather protection provided by the weather flap that covers the zip.

We achieved an exceptional fit with the install and have had confirmation from the client that as well as being thrilled with the look of the cover, the boat was “spotless” after a 1200km drive. We consider that a job well done.

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