Construction and Set Up of theMould FramesThere are many excellent resources that describe mouldframe construction and set up procedures in detail. Hereare a few recommendations ATL Composites make dueto the unique nature of the DuraKore Strip Compositetechnique.

• Make certain the material you use to build the mouldframes (such as plywood or chip board) will hold thescrews or nails you will use to attach the DuraKore stripplanks.

• DuraKore generally requires fewer mould frames thanother methods of one-off construction. The mouldframes can be spaced up to 1050mm apart, dependingon hull shape and DuraKore thickness. In areas of greatestcurvature, additional mould frames should be used. Ifpossible, discuss mould frame spacing with the designerof your particular boat or the technical staff atATL Composites.

• When using male mould frames, do not position themdirectly on the floor, but rather attach them to a strong-back that is high enough off the floor to allow access tothe interior of the hull, even after all the DuraKore stripplanks are attached. This will enable you to scrape offexcess epoxy that squeezes from between the stripsbefore it hardens.

Basics of Boat BuildingBefore unpacking DuraKore, you must build the mouldframes to which DuraKore will be attached. Mould frameconstruction and frame set up are covered very thoroughlyin “The Gougeon Brothers on Boat Construction”.Lofting is the process of translating the small scale linesfrom the designer’s drawings into the full scale of theactual boat size. It is a complex, time consumingprocedure, and a critical procedure that affects the finalappearance and performance of a boat. While some willwant to perform this task, many (especially first timebuilders) may wish to have CNC routed frames suppliedby ATL Composites if their plans are computer generated.

Before lofting, or ordering CNC routed frames, andconstructing mould frames, you must decide betweenusing a male mould or a female mould configuration. Ina male mould configuration, the boat is built upsidedown, over the mould frames. In a female configuration,the boat is built right side up, on the inner of the mouldframes. Each has its advantages and disadvantages.

3

Male Mould FramesWhen using male mould frames, a boat is built upsidedown by attaching DuraKore strips to the outer of theframes, laminating the outer skin, removing the hull fromthe frames and turning it over, then laminating the innerskin and adding stringers, bulkheads and interiorframing.

Advantages :

• It is much easier to work from the outside of the boatwhile attaching the DuraKore strips.

• The hull needs to be turned only once; after laminatingand finishing the outer skin.

Disadvantages :

• The hull structure can lose shape if pulled from themould frames during the turning procedure, so a numberof the temporary mould frames must be left in placewhen turning, or a number of permanent mould frames(such as bulkheads) must be incorporated in the mouldframe set up.

• When building over male mould frames you must crawlunderneath the overturned hull form to scrape excessepoxy/filler that squeezes from beneath each strip plank;or, if left until after turning, you must sand the curedexcess before proceeding with lamination.

• Once the temporary mould frames are constructedand set up, cover all edges that the DuraKore stripplanks will be attached with plastic packaging tape. Thisprevents any epoxy that squeezes out from adhering tothe temporary mould frames.

Company Details

Company Name

ABN

Established

Location

Phone

Fax

Email

Quality Certifications

DNV·GL

Shop Approval #KBZ1095HH

for the Production of Compos�e Panels

ATL Composites Pty Ltd

26 002 517 777

1977

12-14 Production Ave.

Molendinar OLD,

Australia 4214

+61 7 5563 1222

+61 7 5563 1585

info@atlcomposites.com

ATL composites

www.atlcomposites.com