The Making of
The New Montgomery 23 Offshore Cutter
Part Four - Continuing Production

Text provided by Bob Eeg, builder

Click on the half-scale image (~10 kb) to see the full-scale picture (~60 kb.)

Continued 5/28/2002:

The following flow of construction photos includes construction details that had to be finished in steps before other details could be completed. So the photos are not in exact sequence, but close.


The laid-up deck.


We fit white wood and teak sideliners to the deck...


We remove the finished deck and she is beautiful and strong!


Work continues on the deck.


This is a partial interior view of the deck. Notice the bronze ports, teak side liners, white wood. We will add teak trim after she's on the hull.


While we were finishing the deck we were working on the centerboard final shape, the centerboard trunk and the interior grid pan, all at the same time. Here's a shot of the centerboard plug that will be used to cast the bronze bulletproof board. This board will last 50 years without problems (yeah, it's expensive).


We decide to really build a bulletproof centerboard trunk to house this bronze centerboard that will supplement the 1200 pounds of lead ballast. We figure the board will weigh 450 pounds for a total ballast of 1650 pounds. With this weight, the boat will be stiff and weatherly. The trunk has to be perfect so we decide to built the mold for the trunk out of aluminum. Here we have cut the perfect shape and it's being welded.


The centerboard before Jerry grinds and shapes the radius and mounts it on a pedestal for layup.


The centerboard trunk laid up over the mold.


Here we use a fixture to place the centerboard trunk correctly in the hull. Then we glass it in place and add ballast.


The trunk is in. The 1200 pounds of pure lead ballast is installed. Several layers of fiberglass between the ballast and also over the top, overlapping the hull. Very strong.


Meanwhile, while we are doing deck chores, centerboard trunk and centerboard work, Jerry has been busy with the interior grid pan. This was a lot of work (thanks Jerry). Here's Bob applying PVA to the mold before he sprays it.


Bob spraying the interior grid pan.


The interior grid pan is all ivory.


Here's the interior grid pan on its side after being removed from the mold. Notice the grid pattern, that will be double-bonded into the interior of the hull. This makes for a very strong boat. We're building this boat for rough water, no flexing allowed.


A full view of the interior grid pan on the floor.


Close up of the entry (steps) and galley area.


Interior grid pan installed (fitted perfectly and then bonded) into hull. Remember that the ballast (1200 pounds of pure lead) and the beefy centerboard trunk are already installed.


This nifty 10HP Yanmar Diesel arrived. She's a beautiful little engine and we set her in place after the interior grid pan goes in. We spend lots of time on locating places for water and fuel tanks, filters, wiring, galley amenities, etc. This engine will run at full power (you usually never run at full RPM but usually 60% of full power when motoring, but fuel flow is measured at full power) for 3 hours and 20 minutes on one gallon of fuel.


You can just see the engine if you look. We're busy bonding and messing with details. Is it time?


Time to pull the hull out of the mold! We move the mold to the hoist area out back and here she is!


Notice the Lyle Hess-designed beautiful, seaworthy sheer. Thanks Lyle!


Natalie, Bob's daughter, directs the move from the hoist to the shop.


Outside giving us a side view. This is a big 23 footer. She sure is beautiful.


Into the shop


Time now to get her decked....up she goes.


Here's the 23 with her deck. Add a bowsprit, boomkin, teak caprails, chainplates, a green sheer and boot stripe and you will see a very salty-looking Lyle C. Hess Cutter.


Another view. The 23 will have beautiful teak caprails also.


A front view. We have lots to do so stay tuned for the finishing details of the Montgomery 23 Offshore Cutter. Thanks Bob, Jerry, and the crew at http://www.Montgomeryboats.com, (949) 489-8227.



On to Part Five: Production and Assembly...

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