Note. Click on each small picture of vessel on the left to bring up the larger picture and standard specifications of the model
STEPPA FACTORY CONSTRUCTION TECHNIQUES
Our fiberglass layup methods of vessel construction have been carefully developed over the past 18 years (starting on the beach in Bang Tao in 1990).
STEPPA BOAT FACTORY IN PHUKET TOWN
All of our “Steppa” models are constructed using proven polyurethane resin and glass fiber construction methods. We use hand lay-up procedures in the construction of all our parts. Our methods are not fast, but they produce an exceptionally strong light-weight boat.
Gelcoat Process:
We work from the outside in when molding a boat, starting with a great paint job. The first step is to clean and wax the mold to prevent our "part" from sticking to the female mold. The selected color of gelcoat is then sprayed onto the mold surface, followed by a coat of rolled on resin to secure the gelcoat. The black or red "backing" mould color allows our laminators to see air pockets and coat thickness more easily, so they can produce a high quality initial covering laminate.
REDDING THE PLUG TO MAKE THE CAT MOLD
When the gelcoat and first securing resin coat are cured, the mold is ready for laminating with our proven hand-laminating process.
Laminating Process:
Using our supervised hand lay-up method on all vessel parts, multiple layers of fiberglass matt and woven-roving are laid into the mold and 'wetted-out' with fiberglass resins until the desired thickness of the part is reached.
We usually lay only one fiber layer per day in our hull, deck and flybridge moulds. We grind out any imperfections before the next layers are laid. We are painstaking and through during this process making sure to avoid any airpockets or dry patches within our laminates. It would be faster and far more economical for us to use a chopper gun to lay-up, but we refuse as we are committed to this quality process of boat-building. We ensure that all our boats are of impeccable hand laid quality All our ‘STEPPA BOAT’ hulls stand the test of time because we refuse to compromise during this lamination process.
.jpg)
The ‘STEPPA BOAT'S" five main components - hull, main deck, transom-engine-well, floor stingers and flybridge are all laid-up separately. Once the hull has been cast, the integral floor stringer part is added, strengthening the hull both laterally and longitudinally. When the floor part is locked in the hull is ‘pulled’ from the mould. The main deck is also strengthened in the same way before being ‘pulled’ from its mould.
FAIRING "STEPPA-CAT 3500" PLUG FOR MAKING MOLD
Then we lift the deck and bond it to the hull. The main deck is one piece strengthened by closed cell foam sandwich or end-grain balsa and forms the top back-bone of the “Steppa”. Now the flybridge and engine wells are “pulled” from their moulds and fastened and fiberglassed to the transom and cabin top. All parts are then fiberglassed together. Now it looks like a boat!
Sanding Process.
All major fiberglass components within each piece are strengthened with “bones’ of rigid fiberglass u-shaped conduit while still in the molds to insure proper alignment and to eliminate any twist to the hull or parts.
When the boat is fully together it is literally one big piece of fiberglass. It looks semi- finished on the outside; the inside however is still very rough, and is missing many details.
In the sanding process, patterns for hatches and other openings are placed over the shell, and the openings are then cutout. We use full fiberglass flat panels from our huge table moulds to create the bulkheads, toilet walls, floors and seat panels. The cabin door-frame, anchor locker well and hatches, bowsprit and other small moulded and cut fiber panel details are then fiberglassed into place.
Finishing process..
Stainless steel fuel-tanks, bowrails, top deck bimini cover and perspex frames, top deck seating, ladder, grab rails and swim ladders are all made on site at our welding shop.
First using the large access in the original deck (inside cabin) we install the stainless steel fuel tanks, fit them with inspection and cleaning hatches, fuel gauges, intakes and breathing outlet. We also fit the water tank under the forward seating section floor
These fuel tanks are made to order for each boat and customer from our workshop. This ensures a perfect fit. They are now placed on fiberglass spacers keeping them off the hull and locked into position secured in place with fiberglass bulkheads. All deck openings are now covered with a removable fiberglass reinforced floor panel.
Depending on the clients wishes the interior cabin panels are either teak covered or flow coat ‘flecked’ with both gray and black gelcoat to give a unique and maintenance free interior surface.
While the tanks are going in, the windows, railings and deck hardware are being installed topside. Interior cabinetry is being assembled and wiring harnesses are being made to fit the individual customers order. Diveboats have tank racks fitted under stainless seats, taxi boats have airline seating installed, private boats have dining tables fitted etc.
On ‘Steppa’ flybridge versions the control harnesses are fed through a 4 inch circular stainless compression post fitted in the center of the main cabin or run through the floor to come aft of the cabin top. The compression post ( if used ) carries all the electrical, throttle and gear cables to the lower deck and aft engines. It also serves as a strengthening compression fitting between flybridge and main decks and is a handy grab post in heavy weather.
Once the access panels and doors are fitted and in place any interior cabinetry is installed. The installation of the electrical systems and panels is next with all lights, outlets and bilge pumps etc coming to the interior starboard bulkhead in a neat 12 volt fuse and breaker panel. The plumbing of the toilet and afterdeck shower, fuel systems and bilge pumps are done next. Now we clean up, inside and out, and then we install the upholstery.
The last addition is the installation of the outboard engines. We assist the supplier here and make sure all is in order ready for the sea trial.
We’ve put a lot of thought into the designs of our “STEPPA BOATS" We’ve made them easy to operate and cheap to maintain. We did this because we required the strongest, safest, most cost efficient and practical boats for our own 5 star hotel cruise and scuba diving operations.
We continue to improve our designs with every new build. Our easily removable fuel tanks and easy to reach fittings make sure we have no costly downtime during the busy seasons. All pieces of the boat are easily removed and therefore easily replaced.
We are very pleased with the performance of our 100% fiberglass Thai built ‘STEPPA' designs. They continue to prove themselves in the marketplace as the most rugged and most used vessels operating in the Southern Thailand.
Our “Steppa” boats are currently used for guests operations at Amanpuri, Chedi, Banyan Tree, Sheraton, Allamanda, Phi Phi Palm Beach, Sheraton Krabi, Central Krabi Bay Resort, Six Senses Koh Kut, Evason Resort and Spa Phuket, Layana Koh Lanta, Koh Samui Four Seasons, Koh Lak dive companies and Cape Panwa Hotel.
STEPPA CENTER-CONSOLE 36 - FINAL TOUCHES
We have constructed dozens of private vessels custom-built for local owners in Thailand.
The STEPPA BOATS in daily commercial use are our only marketing tool. They accumulate thousands of operating hours yearly incurring low maintenance cost to their owners.
All our boats will be around for many more decades - because we build them super-safe and super-strong.
Visit our factory anytime to see how we put them together.
To contact us for a quote or any questions please call Bill on 081-8912895 or Tony on 081-8912688 or email us here!
|
