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How We Build Your Half Hull

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All of our hulls are hand crafted, one at a time, using the "plank on frame" technique, a traditional method used throughout the millennia. We now offer some of our more popular halfhulls in resin.
Plank-on-Frame Ready to
Each of our hulls is built to scale and crafted of wood. The internal framework of your replica is constructed using a variety of one or more of the following woods: bass, pine, plywood, walnut and/or oak. Any external trim is duplicated using the same type wood as is on your boat (teak, mahogany, oak, etc.).
After laying the bulkheads and frames, the hull lines are trued in preparation for "planking" with individual strips of wood. Once your model is planked, we then begin building up the surface.  We do this primarily by spraying on a heavy coat of paint, allowing it to cure, then we wet sand. We repeat this process numerous times until the hull is as smooth as glass.
Sizing to original plans
  The final coat of paint is applied to match your hull color as closely as possible.  We can also add the non-fouling bottom color if you prefer.  Finally, we add the cove and boot stripe colors to complete your hull.
J 35 Full Model Cockpit Detail
Full hulls are crafted using the same process as each of our half hulls. After the hull is completed, we add as many details as possible. We use polished stainless steel for parts such as the wheel, vent guards, and stanchions; aluminum for the boom and mast. The toe rails are teak, aluminum or mahogany depending on those on your boat.  And finally, accurate deck hardware and rigging is used to complete your replica.
(800) 266-7054
  (770) 521-0605
jim@halfhulls.com
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