Outline moulding procedure

The following steps are a description of the procedure we follow in our workshop. 1) First we build a plug - this is an exact copy of the exterior surface of what the final product would be. It can be made out of different materials like Foam, wood, etc. Its finished surface should be absolutely perfect. Sprayed and sanded to perfection. Any blemish here will transfer to every single that make in the future, therefore every blemish is treated now. 2) Then the plug is being coated with a release agent (wax or special chemicals) 3) Application of special mould making gelcoat to the plug 4) Application of many layers of fibreglass over the plug to build a strong mould using best practices for doing so. 5) Build and attach supporting structure for the mould to ensure its stiffness and allow for easier access and handling. This structure can be quite simple or sophisticated depending on the needs. 6) Remove the plug from the new mould 7) Coating of the new mould with release agent 8) Spray in the gelcoat 9) Application of layers of FRP as specified in the design 10) Stringers, frames, and other internal structure are added and laminate them accordingly 11) Grinding/sanding the inside in order to remove roughness 12) Spray the inside of the new boat with a waxed air dry gelcoat to give it a finished look 13) Remove the new hull from the mould and proceed to fit out.