Our tooling project for the Sabre 46 Salon Express is advancing quickly at Marine Concepts' shop. Our in-house designers are now ensconced in the details of the deck mold while the hull plug (seen here) is off and running.
The process involves creating the basic shape of the hull as designed, using wooden frames representing the shape of the hull at each station. Once the basic shape is built it is sprayed with foam and then the entire part of placed on the five axis milling machine. From there the router takes over and follows the precise lines as created by the hull designer to create the form or plug as it is better known.
There are some very special details in this hull design, none of which we can tell you about because of their proprietary nature, but once you sea trial her you'll know what I am talking about. The design is being specifically detailed for the Zeus pod drive system.
In this stage of the plug build a technician is applying a layer of fiberglass to the exterior which will be worked down to the final finish
Everything is on schedule for this hull plug to be transformed into a mold and arrive in our shop in Maine in late August.