Chicago Marine Canvas

Project Details

Fabric 1

Producer: Serge Ferrari North America Inc.
Supplier: Trivantage LLC

Fabric 2

Producer: Strataglass LLC
Supplier: Keyston Bros.

Fabric 3

Producer: OTHER
Supplier: Keyston Bros.

Please describe the project specifications

The project was broken into two stages. The first stage was the boat top which was fabricated of Stamiod Heavy Royal Blue 102" sewn with Gore Tenara HTR 138 8 oz. thread. The top was laced to the frame via grommets which were all hidden on the underside. The second stage was to create an efficient and independent process to mount forward, port and starboard enclosure panels. Before we measured we decided on the amount of panels we would need and boxed them out on the frame with Crocodile Keder Rail Curtain Track Aluminum. We then measured the frame/Keder tracks with a Proliner and designed the panels in Rhinoceros CAD software utilizing Exactflat. The forward panels and 1st third of the port/starboard where constructed of Makrolon AR2 abrasion resistant polycarbonate. The remaining port/starboard panels going aft were constructed of Strataglass 40 gauge. All panels where attached to the Marine Keder on each side of the panel with YKK #10 zippers so each panels could be taken on and off independently (but all overlapping). Zippers were also hidden to the customers view to avoid the temptation of "seeing if they worked" while underway......

What was the purpose of this project? What did the client request?

The customer required a commercial grade top and enclosure to keep over 20,000 customers warm while in transit to and from an island bar which they operated. The pontoon would make up to 15 round trips per day and deckhands would need to be able to take on/off the enclosure panels during inclement weather. In addition to the panels being easy to take on/off they needed to have a complete seal especially around the 3 entrances/exits.

What is unique or complex about the project?

The project was challenging in multiple areas. Sewing both the boat top and some of the larger panels required someone to assist the seamstress in moving the fabric across the table which sewing. The owner also required proper airflow to eliminate any fogging while underway so we created a vent/passage between the top and froward Makrolon panels. Safety was also a concern and we needed to have precise cutouts for navigation and flood lights for the vessel. Everything on the enclosure needed to be over-engineered and reinforced to withstand these party-goers all summer long!

What were the results of the project?

The results of the enclosure were fantastic. The boat captains and owner were very pleased with the outcome. The forward Makrolon AR2 panels had minimal glare at night and performed extremely well at speeds of 30 knots. The customer and passengers all commented on how noticeably "cool" it was under the royal blue cover versus the other boat they maintained which has a white cover. I learned that the Stamoid Heavy is manufactured specifically to reflect the sun and keep the underneath cool. We now have an order in place to fabricate the same enclosure for their sister ship next summer.

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