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Listed below is the Wyliecat Factory and the basic building process used throughout the Wyliecat line. Page one of three.

Wyliecat Factory 1An empty Wyliecat 17 mold.
In the foreground is the empty hull mold for the Wyliecat 17. The red line is a guide for the different colors of gelcoat. Also visible in this photo are a few other Wyliecat's under construction at the factory. In the background you can see a nearly-complete Wyliecat 65, SRV “Derek M. Baylis”, and on the left is the bow of a Wyliecat 30.


  Wyliecat Factory  2White gelcoat is sprayed on below the waterline.
The first step is to apply a wax release to the mold so the hull can be easily removed when finished. After tapping off the area above the waterline, white gelcoat is sprayed into the hull mold.
  Wyliecat Factory 3Blue gelcoat is applied above the waterline.
Once the white gelcoat has been applied to the area below the waterline, it is tapped off. Blue gelcoat is then sprayed onto the topsides of the hull mold.
  Wyliecat Factory 4First layer of the laminate is hand laid.
After the gelcoat layer has been applied, the first layer of unidirectional E-glass is carefully applied in Vinylester resin. This is superior to polyester because its molecular chain is better able to absorb shock loadings. This makes vinylester resin more resilient, and it also exhibits much better resistance to water which prevents blistering in the hull laminate.
  Wyliecat Factory 5Vacuum bag process underway.
The balsa core components are carefully placed into position on the underside of the deck. Then a special airtight plastic bag is wrapped around the deck and the plastic tubing visible in the photo is attached to a vacuum pump. The vacuum created inside the bag reaches 11 pounds negative pressure. This negative pressure tightly presses the core materials against the deck for superior bonding. After this bonding operation is complete, another layer of fiberglass is added. The end result is a deck that, like the hull, is both lightweight and very rigid.

Wyliecat Factory 6Reinforcements are added to high-stress areas in the deck.
Carbon fiber reinforcement strips are bonded to the underside of the deck to add strength in the mast collar area. The gray material between these strips is G10 high-density epoxy plastic.




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