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Project Details

Fabric 1

Tempotest Marine Fabric
Producer/Manufacturer: The Miami Corp.
Primary Use: Main Fabric

Fabric 2

Aqua-Lite (Makrolon)
Producer/Manufacturer: Manart-Hirsch Co. Inc.
Primary Use: Window

Fabric 3

Strataglass
Producer/Manufacturer: Keyston Bros.
Primary Use: Window

Please describe the project specifications

This project was for a long-time client on their new 450 Sundancer. We fabricated a cantilever camper enclosure on their previous boat and they wanted something similar for this boat. They also had some odd requests, such as adding a skylight to the camper top, and building an "attic" in the camper top for storing the panels when they want to open up the boat. Unfortunately these requests would have resulted in the top being susceptible to leaking and storing the windows in an attic would damage them. However, one of their main requests was to have the enclosure not be as dark as their previous one, which used navy colored fabric. Since they wanted the skylight to see the sky through the roof, we suggested that they allow us to build a two-tone top with light blue on the inside and gray on the outside. They really liked this idea so we went for it. The camper frame is built from 1.25" tubing that had to be extended because the total length exceeded the 24ft lengths of tubing that we can purchase. We had to use a slightly smaller piece of tubing and insert it halfway into the 1.25" on one side, and then add another section of 1.25" tubing to the other side. The pieces were then riveted together to ensure that there was no rattling, flex, or other concerns. The fabric the clients selected is only available in 46" widths, so we had to cut a total of 26 pieces of fabric (13 gray, 13 blue) for the camper top, and 12 pieces of fabric (6 gray and 6 blue) for the bimini top, not including the additional pieces cut for the visor, zipper pockets and reinforcements. We laminated the pieces together after cutting them out, and stay stitched them to ensure they stayed in place while fabricating.

The original bimini was too low and you would have to duck down to at the helm so we also bent a new two bow bimini frame using 1" stainless steel to allow the operator to stand while running the boat. The front windows are .060 polycarbonate, as are the triangle windows behind the radar arch. The rest of the camper enclosure is .040 Strataglass with screens in the two side windows and the two large back windows. We used a darker gray for the binding to add some more pop when looking at it from outside and it also provides a great accent color to the blue on the inside. We also fabricated a front window cover to block out sunlight from the helm area and protect the windows.

What is unique or complex about the project?

We are submitting this project because it was a unique complicated challenge. Laminating fabric for the two-tone tops was a learning experience and thankfully we were able to call a colleague who has done similar projects for guidance. Some finesse is required when applying the glue to ensure that it doesn't coat the fabric and show a wet stain through the material, or you have to throw it away and start again. Cutting, gluing, and fabricating a top that uses 26 pieces of material is a time consuming process and results in a much heavier top than usual and you have to be conscious of sagging. This project was scanned with our Proliner and cut on our cutting table, so thankfully cutting the pieces was faster than if it had been done through traditional patterning. Since the camper is a cantilever frame, there is also the challenge of blending the seam line going around the back of the camper frame, which turned out perfect on this project. The end result was a beautiful project and incredibly happy clients. The brightness of the blue inside the boat is really nice and offsets the client's desire to be able to see the blue sky while sitting under the camper top. We have gotten more compliments from this project than any other we have done in our 6 years of experience.

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