- Project Type: ‘Remaster’ – Taking the building blocks from the original builder and bringing it up to a modern standard
- Project Duration: 4 months
A one-of-a-kind bespoke bar –
A statement of exclusivity.
Custom one-off Flybridge bar
We were asked to remove the 2 existing smaller bars on a Princess 35M Flybridge and create 1 large bespoke bar to stand in their place. This would be a much more user friendly, practical and beautiful looking unit. This involved replacing parts of the teak deck, and designing, manufacturing and engineering a fully custom bar unit from Plywood plug to GRP molding.
Design & Engineering
- Concept Design
- Initial sketches and layout to define the overall look, rough sizing, and intended use of the wet bar.
- Detailed & Fit for Manufacture Design
- Refined design including structural layout, material choices, service routes, access points, and technical feasibility. This stage considers every detail – from stone thickness, hinges, and insulation to lighting, drainage, and ventilation.
- 3D Modelling
- Translating concept and technical data into a precise 3D model that aligns with both the design intent and manufacturing constraints.
- Design Review
- Final check of all dimensions, tolerances, and part integration to ensure seamless assembly and manufacturing efficiency.
Plug (Pattern) Creation
- 2D Sectioning
- CNC-cut plywood sections based on the 3D model, offset to allow for cladding thickness. Both horizontal and vertical sections are used for accuracy.
- Fairing & Trial Assembly
- Plug is filled and faired to achieve a smooth finish. All parts are dry-assembled to verify fit.
- CMM Check
- Parts are measured to ensure 1-2mm tolerance accuracy.
- Final Finishing
- The plug is base-coated, sanded, and top-coated to a gloss finish, ready for moulding.
Moulding Process
- Mould Preparation
- Split lines are defined, flanges built, and the plug is sealed and waxed. Multiple gel and mat layers are applied for strength, with foam cores added to large flats.
- Mould Release & Finishing
- Mould is carefully released, cleaned, repaired, and buffed. Sealed and waxed again for production.
Component Moulding
- Laminating
- Moulds are taped and coated with white gelcoat. Layers of mat and core and applied with careful rolling to eliminate voids. Structural UD tapes reinforce long flat areas.
- Joining Splits
- Flanged sections are bolted and joined with fibreglass, ensuring smooth, staggered seams.
- Post-Cure
- Mouldings are heat-cured to 50°C over 12 hours in a controlled oven to stabilise the structure.
Final Finishing
- Release & Repair
- Mouldings are removed, minor repairs made, and post-cured again as needed.
- Prep & Spray
- Surfaces are sanded, parts aligned and hung, then sent for spray finishing. A final cure at 85°C ensures a durable, high-gloss finish
- Assembly
- All components are carefully assembled and tested to ensure perfect fit and function aboard the yacht
Additional Works
- Cockpit bar front in the same style as new Flybridge bar
- Reupholster Lower Companionway bulkheads to brighten the area
- Cabin doors leather insets to match new Companionway lighter fabrics
- Master Cabin window liners recover due to de-lamination
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