More Than Just a Pretty Face Page 2

More Than Just a Pretty Face

Part 2: The entire massive deckhouse was designed to be removable.

By George L. Petrie

 More of this Feature

• Part 1: Carver Marquis
• Part 2: Carver Marquis
• Part 3: Carver Marquis
• The Marquis Team
• Carver Marquis Photo Gallery

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In other disciplines, most notably joinery, varnish, and the final integration and assembly lines, Marquis production facilities are totally separate. Nevertheless, a degree of cross-pollination is inevitable and, the company says, should ultimately lead to the betterment of both product lines.

One of the biggest challenges facing the Marquis team was figuring out how to fabricate the deckhouse, which has a lot of complex shapes, sculpted surfaces, window insets, and multiple styling features, like the faux vents at the aft end on each side. The easy solution would have been to mold the deckhouse in several pieces, but the consequent seams would have required caulking that might have spoiled the yachts’ clean lines. Instead, the deckhouse is one giant piece, from a single mold, albeit one of mind-numbing complexity. There are no fewer than 57 discrete components that form the intricate sweeps, nooks, and crannies that comprise her shape. After lamination is complete, a multitude of articulated sections are hydraulically retracted so that the massive fiberglass piece can be removed from the mold. It’s something to see.

Another critical construction detail in any yacht is the method of joining the hull and deckhouse, and in building the Marquis, Carver opted for many long-established procedures that it uses throughout its product line. But rather than molding the side decks as part of the deckhouse and then attaching the whole unit to the top of the hull, as it does with the Carvers, the builder molds a separate “cap deck” that spans the width of the hull, lapping the hull sides like a lid on a jar. It’s a 1 1/2-inch-thick laminate joined to the hull by mechanical fasteners spaced two to four inches apart and supported from beneath by transverse bulkheads. As a result, the cap deck forms a rigid foundation for the deckhouse while eliminating an area of potentially high stress along the inboard edge of the side decks.

But the Marquis 65 takes the process a step farther. Because the complete yacht would be too tall for over-the-road transport, her entire massive deckhouse was designed to be removable. Fitted with a separate cap deck on its underside and quick connects for plumbing and electrical connections, the complete unit can be lifted and transported as a self-contained unit—with all finished interior joinery and furnishings in place. And once the deckhouse is installed, the double cap deck forms a massively strong internal structural member.

Next page > Part 3: To eliminate dust and imperfections on the surface, each final coat is applied inside a fully enclosed spray booth. > Page 1, 2, 3, 4, 5

This article originally appeared in the August 2004 issue of Power & Motoryacht magazine.

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