Company:
Kastelic Canvas

Project Details

Fabric 1

Sunbrella Crest Ash
Producer/Manufacturer: Trivantage LLC
Primary Use: Main Fabric

Fabric 2

30 mil verilon clear vinyl
Producer/Manufacturer: Trivantage LLC
Primary Use: Secondary Fabric

Fabric 3

30 ga. Strataglass
Producer/Manufacturer: Trivantage LLC
Primary Use: Additional Fabric

Fabric 4

YKK zippers
Producer/Manufacturer: Trivantage LLC
Primary Use: Hardware/Findings

Fabric 5

Phifer 72-inch Fiberglass screen
Producer/Manufacturer: Trivantage LLC
Primary Use: Additional Fabric


Design Name
Mark Muehlfelt

Design Company
Kastelic Canvas

Fabrication Name
Mark Muehlfelt

Fabrication Company
Kastelic Canvas

Installation Name
James Martillaro

Installation Company
Kastelic Canvas


Please describe the project specifications

The client wanted us to fabricate a dodger top as well as a bimini and enclosure for their Passport 47 ft. sailboat using their existing framework. The boat was located on the water 65 miles away and could not be trailered, meaning we would have to template, fabricate and install the enclosure offsite. We have fabricated enclosures before for boats less than 30 foot long, but NEVER for a sailboat. In addition, our customers usually bring the boat to us to work on, as opposed to us having to travel to the boat. We were hesitant, at first, to accept the job, but the customer had talked to us at the Boat Show and was impressed with our work. They said they were moving out of state in July and didn't trust anyone else to complete the job.

The customer was looking for an enclosure that would protect while sailing down to the Caribbean. This included windows as large as possible, cut-outs and zippered access areas for the numerous lines (which we are not accustomed to with power boats), screened panels with u-shaped zippered windows, and custom fit front windows that zippered to the dodger frame. The entire enclosure had to be secured with turn-button fasteners.

It took us over eight hours in 20 mph winds for us to plastic template the boat. After three more trips for installation and slight modifications, we were able to finish the boat enclosure on time. The customer has since texted me saying how he loves the boat enclosure and he even sent me a video of himself in the enclosure sailing in the driving rain.


What is unique or complex about the project?

We entered this project because of the difficulty level of the enclosure. While we were familiar with enclosures, there were many times where we had to think out of the box to satisfy the customer needs. The most challenging required sewing zippers along the front face of the dodger top in order to attach the front enclosure panels. The other added difficulty was having the boat 65 miles away sitting on the water outside.


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