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Project Details

Fabric 1

Stamoid Open
Producer/Manufacturer: Serge Ferrari North America Inc.
Primary Use: Main Fabric

Fabric 2

AquaGlas
Producer/Manufacturer: Piedmont Plastics
Primary Use: Clear Acrylic

Fabric 3

Trimtrack
Producer/Manufacturer: Makefast
Primary Use: Hardware/Findings

Fabric 4

Costa Track
Producer/Manufacturer: Costa Marine
Primary Use: Hardware/Findings

Fabric 5

Keder
Producer/Manufacturer: Keder Solutions
Primary Use: Webbing/Narrow Fabric

Design Name
Derek Newcombe

Design Company
SALTY BUOY Marine Canvas Inc.

Fabrication Name
Derek Newcombe; Andrew Thompson

Fabrication Company
SALTY BUOY Marine Canvas Inc.; Brenco Metal Fabrication

Installation Name
Derek Newcombe, Luke Browne; Cillian McMullan

Installation Company
SALTY BUOY Marine Canvas Inc.; Flagship Yacht Charters LLC

Please describe the project specifications

Bringing a Captain’s vision to life, this project transformed an initial concept into a fully realized enclosure system, engineered for seamless multi-season adaptability. The development process required expertise across multiple disciplines, including prototype scale modeling to refining design details; conducting research and development on bonding PVC to clear acrylic; creating and sourcing custom components from local manufacturers alongside materials from international suppliers. Every aspect was carefully planned to ensure that both functionality and luxury aesthetics were upheld to meet the high standards of a world-class cruising yacht.

MV Last Call, an Intermarine 120 model measuring 40.2 meters, arrived in Vancouver, BC, for an extensive refit. As part of this overhaul, the yacht’s charter company sought to enhance its sundeck enclosure, enabling adaptable seasonal functionality for voyages from Alaska to Mexico—without requiring full panel removal and storage. Based on preliminary discussions with the refit Captain, the design took shape as a three-sided enclosure, consisting of four panels per side. The outermost panels remained fixed, while the adjacent inner panels could slide behind them, allowing effortless transitions between open-air and enclosed configurations. The enclosure initially spanned 16 feet per side and 18 feet across the front, with a height of approximately 3.5 feet from the hard top to the surrounding railing.

Several months after completing the forward enclosure, the project scope expanded to include the aft section of the sundeck, creating an enclosed, heated space for additional comfort. The newly enclosed area measured 5 feet per side and 18 feet across, with a height of 6.5 feet from the hard top to the deck. Upon final completion, the entire enclosure encompassed nearly 80 linear feet, reinforcing MV Last Call’s ability to serve as a year-round luxury charter vessel while demonstrating the seamless integration of innovative engineering and refined aesthetics.

Developing a fastening system for the sundeck’s enclosure presented one of the most complex challenges. The polished stainless-steel railing, enhanced with smoked acrylic panels, eliminated conventional installation methods. To overcome this, a keder-to-zipper mechanism was devised, using Makefast SS Trimtrack mounted on CNC-cut 316 stainless steel ornamental brackets. These brackets were meticulously designed to align with the mounting tabs of the smoked acrylic panels, ensuring that the final installation appeared as though it had been part of the yacht’s original design.

Beyond structural considerations, functionality was paramount, particularly in how guests and crew would navigate the enclosure. The spiral staircase aft provided access, presenting distinct usability challenges. A guest heading to the jacuzzi with a cocktail in hand needed to open the enclosure effortlessly with one free hand, while serving crew required full-width access to move through unimpeded. To accommodate these needs, the entry system incorporated a hockey-stick zippered path, allowing single-handed operation. Additionally, a parallel second rail enabled the door panel to slide left or right behind the adjacent panel, ensuring an expanded passageway for service operations.

The completion of this project did more than deliver a multi-season enclosure—it set a new benchmark in custom yacht engineering. With nearly 80 linear feet of refined craftsmanship, the enclosure enhanced MV Last Call’s adaptability, demonstrating how complex challenges can be transformed into seamless solutions. Through thoughtful design and technical expertise, this project showcases the capability to engineer sophisticated, custom hardware and enclosure systems, reinforcing confidence among shipyards and yacht captains.

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