BUILDING FROM A PRECUT KIT

design techniquesand use it for automatic comp u t e r - c o n t r o l l e d c u t t i n g . T h e r e are m a n y steps

b e t w e e n c r e a t i n g the o r i g i n a l design and having
the b o a t cut out on a c o m p u t e r i z e d plasmao x y g e n cutter. If a p a r t i c u l a r design is to be sold
as a precut steel or a l u m i n u m hull, deck, and superstructure package, then this should be decided
at an early design stage. S o m e designs can be converted, but it is preferable to start w i t h automatic
cutting in m i n d .
T h e m a i n steps in p r e p a r i n g a n e w design
for a boat that is destined to be cut out by a computerized p l a s m a - o x y g e n cutter is as follows. It is
usually the customer w h o gets the process started
by contacting the designer w i t h a brief outline of
w h a t they have in m i n d . F u r t h e r correspondence
q u i c k l y e s t a b l i s h e s the c l i e n t ' s w i s h list, which
u s u a l l y i n c l u d e s t h i n g s such as t y p e and style of
boat, i n t e n d e d u s a g e , and o v e r a l l l e n g t h and
beam. Draft limitations should be specified at this
stage.
A c c o m m o d a t i o n r e q u i r e m e n t s , including
t h e n u m b e r o f r e g u l a r c r e w v e r s u s occasional
g u e s t s , s h o u l d b e defined. S p e e d r e q u i r e m e n t s
a r e i m p o r t a n t , as is the c l i e n t ' s a t t i t u d e to fuel
costs. T h i s list m a y n e e d s o m e r e f i n i n g since
s o m e e l e m e n t s m a y conflict w i t h o n e another.
T h e c o m m u n i c a t i o n e n s u r e s the c l i e n t ends u p
w i t h a boat that m e e t s m o s t if n o t all his or her
d e s i r e s and o v e r a l l r e q u i r e m e n t s . So far the
process is v e r y similar to w h a t w o u l d be followed
no m a t t e r which material or b u i l d i n g method was
used to construct the vessel.

ADVANTAGES OF A KIT
You can g e t y o u r b o a t b u i l d i n g project off to a
great start by using a precut steel or a l u m i n u m kit
for any metal sailboat or powerboat. M o d e r n kits
contain accurate precut parts that y o u can e a s i l y
a s s e m b l e into a c o m p l e t e h u l l , deck, and s u p e r structure. T h e latest computer software allows the
designer to model the boat so that extremely accurate computerized files can be prepared to direct
the cutting m a c h i n e s . T h e s e files contain all the
information to facilitate computer-controlled cutting of all the metal parts for y o u r boat. It m a y not
interest the average builder, but a h u g e amount of
work is required to turn a boat plan into a cut-tosize boat kit. E v e r y part has to m a t c h that of its
neighbor exactly, the slots need to be in the correct
locations, and e v e r y t h i n g m u s t f i t t o g e t h e r p e r fectly. All this is necessary to enable y o u to c o m plete the a s s e m b l y of the h u l l , deck, and s u p e r structure w i t h the m i n i m u m of p r o b l e m s . W e ' r e
always amused when we receive a request from an
u n i n f o r m e d c u s t o m e r that g o e s s o m e t h i n g l i k e
this: " B y the way, n o w that I have the plans for
your design, just send me the cutting files."

DESIGNING AND CUTTING

PRECUT METAL BOAT KITS
M a n y of you m a y be surprised that it's not possible to take a r e g u l a r boat p l a n e v e n one that is
already prepared using the latest computer-aided
38

Building from a Precut Kit

Nested plate drawing. Note the number of sheets and the detail and number of the parts.

39

40

Chapter Six

The client and designer then enter into what

can be a s i m p l e a g r e e m e n t w h e r e the d e s i g n e r
agrees to prepare p r e l i m i n a r y plans for the p r o posed vessel for a reasonable (a relative term!) fee.
In our office the p r e l i m i n a r y plan i n c l u d e s lines
plan, general a r r a n g e m e n t d r a w i n g s (consisting
of e x t e r i o r profile, deck p l a n , a c c o m m o d a t i o n
profile, and plan v i e w s ) , plus sufficient c a l c u l a tions to ensure that the final design can meet the
c l i e n t s requirements.
Before a p r e l i m i n a r y plan is p r o d u c e d , the
d e s i g n e r p r o d u c e s a 3-D c o m p u t e r - g e n e r a t e d
model of at least the hull of the vessel. Once the
preliminary plans are completed and both the designer and the client are satisfied with the overall
concept and layout of the vessel, c o m p l e t e plans
for the vessel are prepared.
Next, a comprehensive 3-D computer model
is completed that includes all parts of the hull (in-

c l u d i n g t r a n s o m , k e e l , and r u d d e r ) , all d e c k s ,
cockpits, a c o m p l e t e s u p e r s t r u c t u r e , m a i n i n t e rior b u l k h e a d s , and a n y other features such as a
flybridge, r a d a r arch, and exhaust stack. S p e c i a l
items such as transom steps and other similar features are i n c l u d e d in this m o d e l . D e p e n d i n g on
the complexity of the design, this process can take
between 500 and 600 design man-hours.
F r o m this m o d e l , all the s a l i e n t h y d r o s t a t icssuch as detailed weight calculations to ena b l e m a t e r i a l r e q u i r e m e n t s and f i n a l d i s p l a c e m e n t a r e c a l c u l a t e d . S t a b i l i t y c a l c u l a t i o n s are
also made at this time. D u r i n g this process, finet u n i n g of the m o d e l can be u n d e r t a k e n to m a k e
sure that the finished vessel will m e e t all the d e sign r e q u i r e m e n t s .
W h e n the c o m p r e h e n s i v e 3-D m o d e l i s
completed and checked, copies are provided to a
t e a m o f s p e c i a l i z e d d e s i g n e r s w h o p r e p a r e the

Here we see a typical layout of parts for a powerboat kit. Note the shaped cut stringers.

Building from a Precut Kit

41

The plans that come with the kits include fully detailed measurements for all stages of the kit assembly and construction of the vessel.

f i n a l m o d e l , w h i c h i n c l u d e s all the s c a n t l i n g s
(such as transverse and longitudinal framing, sole
bearers, deck b e a m s , a n d e n g i n e b e d s ) . T h i s
team s e p a r a t e s out all the p a r t s for the frames,
stringers, e n g i n e beds, bulkheads, hull, deck, and
superstructure plating, etc., and adds notches to
the frames a n d b u l k h e a d s before n e s t i n g the
parts on plates.
T h e d e s i g n t e a m n u m b e r s each i t e m and
draws r e f e r e n c e l i n e s on each part to r e p r e s e n t
frame locations, etc. (the n u m b e r s help b u i l d e r s
identify each part, and the lines are used d u r i n g
the assembly process to locate frames and other
structural m e m b e r s ) .
T h e d e s i g n e r then w o r k s out a path for the
computerized p l a s m a - o x y g e n c u t t i n g m a c h i n e .
The path is the point at which the cutter enters the
plate and starts cutting the parts. It must make sure
the parts are cut in the correct order. For instance,
if a window has to be cut from a cabin side, then
the window aperture must be cut before the larger
cabinside part is cut; otherwise any m o v e m e n t in
the cabin side after cutting could cause the window
to be cut in an incorrect location.
Several sheets of assembly drawings are now
prepared. For instance, each frame is shown sep-

arately with all parts clearly numbered, and meas u r e m e n t s are g i v e n to assist in w e l d i n g up the
frames. O t h e r d r a w i n g s show how to set up the
b u i l d i n g j i g s u p p l i e d with the kit. The location
of every part that forms the completed hull, deck,
and superstructure is shown in the various assembly drawings supplied with the kit.
F i n a l l y , all the parts are listed in a s p r e a d sheet program and checked against the drawings
and cutting files. Another designer is s i m u l t a n e o u s l y w o r k i n g on the e n g i n e e r i n g d r a w i n g s for
the e n g i n e room layout. Battery placement, drive
train and b e a r i n g location and sizes, exhaust system, fuel tank sizes and placement are shown in
these d r a w i n g s .
Of course, all of the above steps have to be
carefully checked and the whole design package
c o o r d i n a t e d before the cutting files are released
to the c l i e n t (to have the kit cut l o c a l l y ) or sent
to the c u t t i n g shop that p r o d u c e s o u r kits. In
t e r m s of i n v e s t m e n t we figure that each set of
cutting files and associated plans for a boat of between 36 and 65 feet costs the originating design
office between $ 3 5 , 0 0 0 and $ 5 0 , 0 0 0 . Because this
figure is too large for an individual customer, we
try to group orders for similar kits as well as treat

42

Chapter Six

a large part of the cost as investment against future kit orders.

The size of r e a d i l y a v a i l a b l e p l a t e v a r i e s
from country to country, so s o m e t i m e s it is n e c essary to renest the c u t t i n g files so t h e y fit the
available plate stock. R e n e s t i n g m a y be also r e quired if the size of locally available cutting tables
is less than that of the e q u i p m e n t used to cut the
first kit. Fortunately it only costs a fraction of the
o r i g i n a l e x p e n d i t u r e to r e n e s t the p l a t e s to a n y
convenient size. As you can see from the above,
the amount of careful and intense work required
to turn a e x i s t i n g or new plan into a set of c u t ting files far exceeds the expense in c r e a t i n g the
original design. It's only possible to justify these
costs if a firm can expect to market several kits of
similar design. Often, cutting files for a particular design can be m a d e in such a way as to g i v e
several c u s t o m e r s the custom items they desire.
Some custom items are relatively easy to incorporate in the c u t t i n g files, w h i l e other m o r e - c o m plex c h a n g e s r e q u i r e r e d e s i g n i n g the basic boat
and remaking all the cutting files.
T h e m e t a l - c u t t i n g shop uses the n u m e r i c a l
code ( N C ) cutting files to produce y o u r kit. T h e
kits are cut from preshotblasted and primed steel
(or a l u m i n u m ) and are d e l i v e r e d r e a d y for e a s y
assembly by any c o m p e t e n t welder. T h e p r i m e r

used on the steel kits is e s p e c i a l l y formulated so

that it doesn't give off harmful fumes as y o u weld
the kit together. T h i s p r i m e r doesn't burn off on
the reverse side of the metal in w e l d e d areas. It's
t r u l y a r e m a r k a b l e c o a t i n g u s e d to p r o t e c t the
steel until additional paint is applied.
T h e parts are all nested, i n c l u d i n g all of the
hull, deck, and cabin plating. You can easily assemble the hull, deck, and superstructure. All y o u have
to do is to match each part to the special assembly
plans you receive with the kit. W h e t h e r you decide
to purchase cutting files and have the kit cut locally
will depend on your location. For instance, due to
the availability of excellent cutting facilities in the
Netherlands, most customers in Europe opt to order a precut kit as opposed to cutting files. C o n versely in countries with a high steel import duties,
such as Brazil, then cutting files and plans can be
purchased on a C D . T h e kit is then cut locally.
In our own case we have exported complete
cut kits to the U n i t e d States, C a n a d a , Philippines,
Russia, and m a n y other c o u n t r i e s , i n c l u d i n g a l most all of Europe.
T h e tack-and-weld m e t h o d described below
i s i n m a n y w a y s s i m i l a r t o the s t i t c h - a n d - g l u e
procedure used with plywood. It's a practical and
economical way to get y o u r boatbuilding project
off to a great start. You can achieve a professional

Part of the engineering drawing showing a section of the engine room layout.

Building from a Precut Kit

Computer-controlled automatic cutting machines can cut a complete 50-foot (15 m) boat in about

43

12 hours, but

hundreds of expert operator hours are required to prepare the cutting files on computers.

result, especially if you a l r e a d y have some w e l d ing e x p e r i e n c e . If y o u lack w e l d i n g e x p e r i e n c e ,

then any local person with s u i t a b l e w e l d i n g
k n o w l e d g e can h e l p y o u a s s e m b l e y o u r kit. Of
course, m a n y thousands of boats have been built
from a set of plans and frame patterns, so if there
isn't a kit that meets your r e q u i r e m e n t s , building
from plans is the way to go. N o n e t h e l e s s , if you
can afford a kit, you'll have a hull in the least time
and this alone m a y justify the modest additional
expense. T h e resale value of your boat will be enhanced if y o u can show that the hull w a s b u i l t
from preshotblasted, primed, and computer-controlled precut metal parts.

Steel Kits
In high-quality kits, all steel plates are shotblasted
and p r i m e d with a z i n c - r i c h p r i m e r before cutting. C u t t i n g of p l a t e s is c a r r i e d out with c o m puter-aided lofted surfaces on an N C - d r i v e n
plasma-oxygen cutting machine with a m a x i m u m
plate size of 82 by 10 feet (14 by 3 m ) . T h e best
material is L l o y d ' s - a p p r o v e d , " A " g r a d e , " s h i p building quality," or the equivalent.

T h e kit i n c l u d e s a s e t t i n g - u p jig as well as

detailed assembly plans. All required steel profiles
are also shotblasted and primed with a zinc-rich
primer. Kits are constructed from the steel product specifications mentioned above.
N o r m a l l y , all the plate material is supplied
as a flat pack with m a r k i n g lines e n g r a v e d in
the plate surface (a zinc l i n e ) and part n u m b e r s
painted on the surface. The maximum size is usually 19 feet 6 inches, by 6 feet 6 inches (6 by 2 m).
All steel profiles are supplied in sufficient length
to e n s u r e the m i n i m u m n u m b e r of joints in the
plating. All parts that require forming or bending
are supplied already formed to the correct shape.
T h o s e w h o prefer a l u m i n u m as their basic
building material will be pleased to learn that kits
are available precut from marine-grade materials.

GETTING STARTED
T h e first t h i n g to realize is that the kit differs in
m a n y w a y s from the m e t h o d s you would use to
build a metal boat from scratch. The kit is far superior to a n y t h i n g you could achieve by starting

44

Chapter Six

Bottom plates, supported by jigs, are in position ready to

ceive the first frames. Note preassembled frames at rear.

with the plans and a d e l i v e r y of raw steel p l a t e

and profile bars.
Most metal boats built from scratch are built
upside down; boats built from cut-to-size metal
kits are built upright. Not only is this a more appropriate way to assemble the kit, it also saves the
cost and inconvenience of having to turn the hull.
And here's one very i m p o r t a n t p i e c e of a d v i c e :
You must tack-weld the complete hull, deck, and superstructure together before you run any final welds.
If you don't follow this advice, you'll almost
certainly end up with an un-fair boat r e q u i r i n g a
c o n s i d e r a b l e a m o u n t of filler. In a n y case do not
overweld or try to run long welds at one time.
Your kit may arrive on a flatbed truck or in a
c o n t a i n e r . Kits a r e n o r m a l l y p a c k e d o n p a l l e t s
and can be lifted off the t r a n s p o r t by a s m a l l
c r a n e front-end loader, o r s i m i l a r e q u i p m e n t .
Provided y o u r kit is on a pallet, y o u m a y find it
more convenient to drag y o u r kit from the truck
or c o n t a i n e r , u s i n g a p a i r of p l a n k s as a r a m p .

O n c e y o u h a v e u n l o a d e d y o u r kit, y o u
must keep it covered until a s s e m b l y is u n der w a y
W i t h y o u r kit, y o u s h o u l d r e c e i v e a
p a c k i n g list and l a r g e - s c a l e a s s e m b l y
d r a w i n g s . T h e d r a w i n g s will show all the
parts as flat surfaces g r o u p e d t o g e t h e r as
t h e y w i l l be a s s e m b l e d to m a k e the finished hull. T h e r e will also be a n u m b e r of
d r a w i n g s s h o w i n g the a s s e m b l y of the
f r a m e s . E a c h p a r t w i l l be n u m b e r e d , so
that y o u can c h e c k it a g a i n s t the p a c k i n g
list and the corresponding drawing.
One of y o u r first jobs will be to tackweld the frames together, so m a k e sure y o u
sort the parts and store t h e m in the order
y o u ' l l need them. On larger frames, it m a y
be easier to tack only the bottom sections
of the frames together at this time.
Once y o u ' v e tacked all the frames together, it's time to prepare the building jig.
T h e t r a n s v e r s e profile j i g s w i l l b e s u p ported by the metal "castles" that come as
rep a r t o f y o u r kit. T h e s e t t i n g - u p j i g i s
m e r e l y intended to start things off. It is not
intended to support the boat during the entire
building process. Usually, however, you leave the jig
in p l a c e for the e n t i r e b u i l d i n g p r o g r a m so y o u
can w e l d a flat strip on the top of e a c h w e b to
spread the load of the plate w h e r e it rests on edge
of the plate web. After you have both sides of the
bottom plates tacked together you should con-

The topside plates are simply pulled around to be

tacked together at the bow.

Building from a Precut Kit

45

Most kits come with three or four setting-up jigs as part

of the cut-steel package.

Sort and check the content of your kit as soon as possi-

Another view of one of the setting-up jigs that supports

ble after delivery.

the bottom plates.

sider a d d i n g extra support and b r a c i n g to the jig

structure.
Set up two parallel I b e a m s as shown in the
i n s t r u c t i o n s t h a t c o m e w i t h y o u r kit. T h e s e
beams must be long e n o u g h to accept the n u m b e r
of s u p p o r t j i g s m e n t i o n e d a b o v e . C r o s s - t i e I
beams should be installed at the same location as
indicated to install the support webs. Obviously,
the w h o l e s u p p o r t s t r u c t u r e m u s t be level in all
directions and well braced as it will play a part in
supporting the boat d u r i n g construction.
D o n ' t a t t e m p t to fully w e l d the p l a t e s i n t o

one l e n g t h on the floor. T h e plate joins should

only be t a c k - w e l d e d in three locations: one weld
at the each of the ends of the join, and one in the
center of the join. T h e s e tacks should be no more
than a 1/2 inch (12 m m ) long. If you weld the plates
on the floor, you'll end up with a hard spot in the
h u l l p l a t i n g . S o m e p l a t e s of 1.4 inch (6 m m ) or
h e a v i e r m a t e r i a l m a y need to be beveled before
y o u tack t h e m in p l a c e . You m a y prefer to m a k e
the bevels after you've tack-welded the plates and
before y o u run the final welds. In all eases, good
metal boat b u i l d i n g practices should prevail. Af-

46

Chapter Six

Keels are assembled either in place or separately, as shown here; your plans will advise you of the best method
to use.

ter you have both sides of the b o t t o m p l a t e s

tacked together, y o u should consider a d d i n g extra support and bracing to the structure.
Sailboats with long keels, such as our S p r a y
designs, as well as most powerboats, should have
the keel structure assembled at the same time as
the b o t t o m p l a t i n g , Take c a r e that y o u don't
"squeeze in" the tops of the keel; use the webs as
s p a c e r s . After y o u ' v e p o s i t i o n e d the b o t t o m
plates, the keel sections, and the transverse profile
jigs, you may start to tack-weld the bottom plates
to the keel s i d e s . S a i l b o a t s w i t h d e e p fin-style
keels may have the keel installed after the hull is
completed. The canoe body should be built from
the bottom of the hull upward in a m a n n e r similar to that used to assemble a powerboat hull. T h e
webs can be a r r a n g e d so that t h e y can be added
a l o n g with the rest of the k e e l after r a i s i n g the
hull to the correct elevation.
T h e benefit of using this method is that it allows you to work on the h u l l , deck, and s u p e r structure w h i l e the boat is l o w e r and thus m o r e
accessible. The exact method and order of assembly d e p e n d s on the a v a i l a b i l i t y of lifting e q u i p ment and y o u r g e n e r a l w o r k e n v i r o n m e n t . D e -

tails given below are valid for the g e n e r a l assembly of all hulls.
W i t h most powerboats, y o u can start by l a y ing the bottom plates in the transverse profile jigs
that come with y o u r precut metal kit. T h e frames
w i l l soon be a d d e d at the l o c a t i o n s i n d i c a t e d by
the transverse lines m a r k e d on the plates.
W i t h a n y hull, the first step is to set up the
bottom plates and tack t h e m along the centerline.
Next, start to install the pretacked frames on the
appropriate transverse lines m a r k e d on the plating. F r o m now on, the w h o l e structure will g r o w
upward. T h e better equipped your workshop is
with overhead lifting and h a n d l i n g gear, the e a s ier and m o r e smoothly y o u r job will proceed.
If y o u ' r e in doubt about y o u r w e l d i n g skills,
seek the help of a suitably qualified person at the
earliest stage. T h e r e is a great deal even the most
i n e x p e r i e n c e d person can do to assist a qualified
w e l d e r to a s s e m b l e the kit. G e n e r a l l y , two p e o ple a r e r e q u i r e d t o h a n d l e the l a r g e r p i e c e s o f
m e t a l , so a c t i n g as l a b o r e r to y o u r h i r e d professional m a y be the best route for you.
If y o u have m o d e r a t e l y good w e l d i n g skills,
y o u ' l l find that the kit c o m e s with e n o u g h scrap

Building from a Precut Kit

material to allow you to get in some practice before tackling the assembly of the kit. Don't try to
weld a l u m i n u m or copper-nickel unless you have
the p r o p e r k n o w l e d g e and c o n s i d e r a b l e e x p e r i ence in handling these materials.
T h e m e t a l kits are c o n s t r u c t e d so that the
strength of the finished hull c o m e s from the
buildup of the frames and stringers in interlocking sections. H e a v y and c o n t i n u o u s w e l d i n g of
frames and stringers should be avoided at all times.
After the hull and deck is tack-welded together, the
process of finish welding can proceed without fear
of distortion.
T h e secret of creating a fair hull and deck is
to use a w e l d e r of high enough a m p e r a g e for the
job. W e l d i n g with too l i t t l e a m p e r a g e , and too
slowly, will create lots of heat on the spot and less
p e n e t r a t i o n of the w e l d m a t e r i a l in the s e a m .
T h i s m a y m a k e for a w e a k w e l d and a d d i t i o n a l
grinding to remove excessive weld material. T h i s ,
in turn, may further weaken the weld.

ASSEMBLING THE HULL

For those of you who are new to this type of boatbuilding, there is an early shock in store. H a v i n g
placed the b o t t o m p l a t e s on the j i g , y o u m a y
think t h e y ' r e not g o i n g to fit. Keep the faith!
Start t a c k - w e l d i n g in the middle of, or somewhat

The frames are set on the bottom plate at the premarked

tacked into position.

47

Depending on the design, you may need to use some

mechanical help to pull the bottom plates together.
The plates on this Trawler Yacht 485 were tacked together

without

any problems.

aft of, the m i d d l e of the p l a t e . M a k e sure the

m a r k s on the plates are lined up at all t i m e s . As
y o u work forward and b a c k w a r d from the tackwelded position, you can form the plates to shape
with some h u m a n help or by using a trolley jack
u n d e r n e a t h the area of the plates where they are
t o join. W h e n t h e y touch, t a c k - w e l d them together and move along to the next position.
At the bow, you'll probably need a block and
t a c k l e to pull the sides of the plates together.
S o m e tension will be e x p e r i e n c e d in this area.
Don't forget to secure the positions of any clamps
so that they cannot unexpectedly let go.
Having finished tackw e l d i n g the bottom plates together, start placing the frames
in position on the bottom
plates. Lines on the plate will
indicate the location of the
frames. You may use the scale
d r a w i n g s as a reference. Dep e n d i n g on the l a y o u t of the
bottom stringers on your particular design, you may have to
install some of them as you are
i n s t a l l i n g the bottom frames.
Study the layout of the bottom
framing on y o u r boat plans
station lines and
and it will b e c o m e apparent

48

Chapter Six

Frames have been assembled and erected. You'll find that you'll reach this stage in a few hours.

Close-up of frames shows web floors with T-bar longitudinal supports installed to accept

the plywood cabin sole.

which sequence will work best

for y o u r hull.
Pull up the bottom plates
t o w a r d the frames u n t i l t h e y
fit s n u g l y and tack-weld them.
S t a r t w i t h a frame w h e r e the
plates are least shaped, and
w o r k b a c k w a r d and forward
from t h e r e . If y o u ' v e a s s e m bled the c o m p l e t e frames, as
opposed to the bottoms only,
use t e m p o r a r y braces, as n e c essary, to support the top portions of the frames. O n c e all
the frames are i n s t a l l e d , y o u
m a y f i t s o m e o f the side
stringers into the slots on the
frames. T h e s e s t r i n g e r s w i l l
assist in stiffening up the
s t r u c t u r e a t this s t a g e . O n c e

Building from a Precut Kit

49

The transom in place; the next step will he to install the radius stringers. Photos on pages 49-52 (top) were taken
by Brian Smyth of YachtSmiths International of Nova Scotia,

again: U s e o n l y t a c k - w e l d i n g at this stage of the

assembly process.
T h e next step is to install the side p l a t e s .
T h i s is best d o n e by u s i n g a s i m p l e o v e r h e a d
g a n t r y or a forklift truck.
Pick up the side p l a t e s w i t h
a plate clamp on a chain connected to a block and tackle
made fast to a forklift l e g .
M a k e sure the plate is m o r e
or less in b a l a n c e w h i l e it's
h a n g i n g free of the g r o u n d
before y o u lift it i n t o p o s i tion. U s e a helper to locate a
m a t c h i n g line in the r i g h t
position a n d t a c k - w e l d it.
C o n t i n u e to m o v e the plate
up or d o w n a bit w i t h the
block and tackle until the entire side is in p o s i t i o n and
tack-welded in place. Place
some tack w e l d s on the side
frames-to-plate joint as well
Note the fair line of
as on the chine seam.

Canada.

T h e side plates
side of the bow will
be p u l l e d into place
outside of the plates.

near the how and the undershow some tension, and can
by a t t a c h i n g a chain on the
To attach a chain or a block

the stringers as they are installed into precut slots.

50

Chapter Six

A prefabricated long keel is installed on a Voyager 495 hull.

Building from a Precut Kit

and tackle to a plate, tack-weld
a t e m p o r a r y e y e or s i m i l a r
piece to the plate. By welding
only one side of the e y e , y o u
can easily remove it after use.
Next, the transom plates,
swim p l a t f o r m , stern p l a t e s ,
and all o t h e r p l a t e s that go
into f o r m i n g the hull are installed and tack-welded in position. N o t e that w i t h r a d i u s chine boats, the radius panels
are installed later. R e m e m b e r
to refer to the d r a w i n g s frequently.
N o w the deck plates, superstructure, and items like a
flybridge are installed and
tack-welded into position. Any
deck s t r i n g e r s and cabin top
intercostals in y o u r

Deck stringers help stiffen the structure while the hull is being plated.

Optional twin cockpits and side deck plating installed on a Voyager 4 9 5 .

51

52

Chapter Six
m a y n e e d to be i n s t a l l e d before
the applicable areas of plating. In
some cases, it m a y be possible or
preferable to tack-weld the superstructure together off the boat and
then install it as one unit. Some of
the more recently designed kits allow for this option by p r o v i d i n g
special l a n d i n g a r e a s at each
frame, w h i c h m a k e it s i m p l e to
line up the completed superstructure with the hull and deck.

RADIUS CHINES
View of the pilothouse looking forward from the cockpit and poop deck.

This Voyager 4 9 5 was cut in Chile using cutting files and assembled with
the aid of the comprehensive plans that accompanied the files by
owner/builder

Bernie Loyer.

After y o u ' v e t a c k - w e l d e d the ent i r e b o a t t o g e t h e r , it's t i m e to

tackle the radius chines. W e ' v e
always maintained that radiuschine hulls should be built upside d o w n . F o r o n e - o f f b o a t s
b u i l t from s c r a t c h , t h i s a d v i c e
still s t a n d s . But, b e c a u s e all k i t
boats are b u i l t u p r i g h t , a special
approach is required to enable
the r a d i u s c h i n e s to be fitted
without blemish. At first, we
supplied the r a d i u s p l a t e s r o l l e d
in one d i r e c t i o n only; this is the
s a m e rolled plate y o u w o u l d use
in one-off radius construction.
W e soon discovered w h y w e had
a l w a y s insisted that these r a d i u s chine boats should be built inverted. Fortunately, we w e r e able
to solve the problem. T h e radiuschine boats built from these kits
a r e still b u i l t u p r i g h t , b u t w i t h
one important difference: we
n o w s u p p l y fully f o r m e d r a d i u s
p l a t e s . T h e y are r o l l e d i n all d i r e c t i o n s to e n s u r e a p e r f e c t fit.
This improved arrangement is
available because it is n o w possible to h a v e the p l a t e s fully
f o r m e d a n d r o l l e d from t h e i n -

Building from a Precut Kit

53

This is the standard of finish you'll be able to achieve if you take care when welding your radius-chine kit, and follow the building instructions to the letter.

formation s u p p l i e d i n the o r i g i n a l m o d e l i n g
files. T h e f o r m i n g c a n n o t b e a c c u r a t e r i g h t t o
the e d g e of the p l a t e , h o w e v e r , so e a c h s e c t i o n
is a little oversized at the edges, w h i c h allows for
exact fitting and t r i m m i n g . Your kit will contain
the appropriate a m o u n t of p r e r o l l e d , n u m b e r e d
sections to fit t h e a r e a c o v e r e d by the r a d i u s
chines.
N o w y o u can carefully place the a p p r o p r i ate p r e r o l l e d section a g a i n s t the position on the
o p e n i n g in the h u l l . U s i n g a helper, s c r i b e the
edges of the plate with a sharp tool or pencil and
then cut, g r i n d , or nibble the e d g e for a perfect
fit. T a c k - w e l d it in p o s i t i o n and c o n t i n u e u n t i l
you have all the radius panels in place.

FINISHING THE ASSEMBLY

T h e first job is to c o m p l e t e the w e l d i n g of the
frame sections and then i n t e r m i t t e n t l y w e l d the
frames and s t r i n g e r to the hull p l a t i n g u s i n g 2inch (50 m m ) weld spaced at 6 inches (150 m m ) .
Do not o v e r w e l d and do not c o n t i n u o u s l y w e l d

on one side of the h u l l . W e l d on a r e a s o n a b l e

amount on one side then switch to the other side,
b a c k and forth until the e n t i r e hull is w e l d e d .
C o n s t a n t l y w o r k i n g from side to side will avoid
the plates pulling out of shape and general distortion that can be caused by o v e r w e l d i n g or w e l d ing entirely on one side at a time.
You should have m a d e a 6 0 - d e g r e e V between the plates, 30 degrees on each plate, but if
you haven't previously prepared the heavier plates
in this manner, you may do so now by running an
a n g l e g r i n d e r a l o n g the appropriate seam. Now
you can proceed to run the final welds on the outside of the p l a t e s . T h e hull below the w a t e r l i n e
must be welded both inside and out. Again, work
from one side of the hull to the other frequently
changing sides.
You can g r i n d off any excess weld m a t e r i a l
by first using a coarse disk and then finishing up
with a softer, more flexible disk, Take advice from
y o u r materials supplier about these items.
Lastly, apply a m i n i m u m of filler to the seams
and a p p l y a coat of p r i m e r to the g r o u n d areas.
You're now ready for final finishing and painting.

54

Chapter Six

T h e r e m a i n d e r of the p a i n t i n g and f i t t i n g - o u t
work is the same whether you build from a kit or
from scratch. One big difference is that by using
a precut kit you'll have saved over 75 percent of
the t i m e r e q u i r e d to b u i l d a s i m i l a r hull from
scratch.

SELECTION OF DESIGNS
Following is a selection of designs that are available as kits or cutting files. Space does not permit
us to show the full range of available kits; for additional information visit www.bruceroberts.com.

EURO

Euro Powerboats
And Motor Yachts
T h i s range of powerboats was designed with
longevity in m i n d . It is c o m m o n k n o w l e d g e that
automobiles are designed with a limited life both
in serviceability and style. Boats, however, should
be as timeless as possible; this rules out e x t r e m e
design features that will "date" the boat in the future. We hope you will agree that the Euro series
meets our desired criteria. We only have space to
illustrate a few of the models in this book, but you
can see the full r a n g e of E u r o p o w e r b o a t s and
motor yachts at www.bruceroberts.com.

1000

Designed to meet a variety of uses, this is the smallest of our powerboat kits and ideal for river, canal,
and (coastal cruising. There are two basic versions, family cruiser and workboat, available either as kits or
cutting files.
L( )A

37' 1 1 / 9 . 7 4 m

LWL

28' 2"/8.89 m

Beam

12' 4 / 3 . 7 6 m

Draft

3' 9/1.14 m

Draft

8' 2'/2.49 m

Displacement

19,000

Power

60-120

lb/8,636

kg

hp

The versatile Euro 1000 is our

smallest kit boat and the main
versions are a family cruiser and
fishing boat/workboat that has
already found many uses among
those looking for a small utility
boat

As with most of our kit boats,

the Euro 1000 is available as a precut kit, with a ready-built hull,

deck, and superstructure, or as
cutting files and assembly plans.

Building from a Precut Kit

This aft cockpit Euro 1200 was built

from a kit we supplied to Henk G. A.
Kregting in the Netherlands.

Henk

has now built several boats from our

kits, including Voyager sailboats as
well as other Euro motor yachts.

EURO

1200

Available with either an aft cockpit or aft cabin

arrangement, this versatile steel kit or cutting files
has already been built in large numbers. As well
as the regular family cruiser versions this design
is available as a workboat, crew boat, or lowprofile,

An aft cabin version of the Euro 1200. This example

was built in the UK by Wilstream Yachts and exhibited at the Southampton boat show.

One of several possible layouts for the Euro

1200.

canal-friendly

cruiser.

LOA

39'

11/11.95

LWL

33'

10/10.33

Beam

13

Draft

3'

5/4.10m

Displacement

39,000

Power

150-200

11/1.20

lb/17,727
hp

kg

56

Chapter Six

The Euro 1400 comes in an aft cockpit version, or an aft cabin version, as shown here.

One of the accommodation arrangements available for the Euro 1400. This version is available as a kit and
also as a complete boat manufactured in Korea,

EURO

the Netherlands, and elsewhere.

1400

This is a larger version of the Euro 1200 featuring both aft cockpit and aft cabin versions, and is available
as a kit or cutting files.
LOA

45' 9 / 1 3 . 9 5 m

LWL

3 8 ' 5/ 1 1 . 7 2 m

beam
Draft
power

8 /4.77 m

15'
]

4 0"/1.20m
250-470

hp

Building from a Precut Kit

The euro 1 6 0 0 has been o n e of our mosT popular kits and is available as cutting files, a kit, or as a partly
or completely built boat from several builders

worldwide.

EURO

1600

Using my self-appointed measurement rule, this is the first of the Euro

series that would merit the designation of motor yacht. Several of these
vessels have already been assembled
from our precut kits and many more
are currently being built in various
countries. Featuring a large aft
owner's stateroom, plus all the usual
accommodation

associated with

vessel of this size, the Euro 1600 has

already found many admirers.
It is currently built as a semidisplacement hull, but is also available
as a planing hull should any client
wish speeds over 16 knots.

The Euro 1600 kit includes preformed stairs from the main deck
down to the accommodations below. This is a common feature in
several of our larger kits.

LOA

5 3 ' 9 / 16.37 m

LWL

4 5 ' 6 / 13.88 m

Beam

17 9/ 5 . 4 7 m

Draft

4' 0 / 1.20 m

Power

450-550

hp

58

Chapter Six

This photo of a

Waverunner 65

EURO

2000

(the prototype for the Euro 2000)

This motor yacht is currently available in a semidisplacement hull

was taken by the owner/builder

configuration and is ideal for those who seek a motor yacht that

from his micro light aircraft in

combines

Cyprus.

stylish package that will assure your pride of ownership. Several of

ultimate comfort with seaworthiness,

all wrapped in a

these yachts have already been built in fiberglass, steel, and aluminum. One of our cut-to-size kits will make this quick and easy
to build. You can build this boat in either steel or aluminum.
Minimum

power

requirement

for

the

semidisplacement

version

would be twin 250 to 500 hp engines with cruising speeds of 12 to

16 knots. A planing version will be available to those who are looking for speeds in excess of 16 knots. In the planing version, twin
1,050 hp engines should be capable of driving this boat to speeds
in excess of 30 knots.
LOA

71 9 / 21.87 m

LWL

6 2 ' 7"/19.01 m

Beam

19' 2/5.84 m

Draft

5' 6"/1.67 m

Displacement

94,105

Power

500-1,200

lb/42,775
hp

kg

Building from a Precut Kit

The Euro 2300 version

is a semidisplacement motor yacht (12-16 knots)

and the Euro 2400 is a planing hull configuration (16-30 knots).

underwater shape of the hull together with

The

the horsepower of the en-

gines governs the performance and cruising speed that you can expect
from this and other similar Euro Series Motor Yachts.

EURO 2300, EURO 2400 (PLANING HULL), EURO 2600

(SAME AS EURO 2300 PLUS FISHING COCKPIT)
These motor yachts

were designed for either charter work,

EURO 2300 SEMIDISPLACEMENT HULL

TO 16 KNOTS):

(12

LOA

77 6 /23.64 m

LWL

69' 3 / 2 1 . 1 2 m

Beam

2 0 ' 2/ 6 . 1 5 m

Draft (hull)

3' 9/1.14 m

Power

corporate

(16-knot

use, or for the family with deeper pockets. Several examples have al-

version)

ready been assembled from

59

700-2,000

hp

either kits or produced locally from cutting

files. All these motor yachts share a similar lines that we feel will ensure
that they will have an up-to-date appearance for many years to come.

EURO 2400 PLANING

HULL (16 TO 30 KNOTS):
LOA

78' 9/23.99 m

LWL

70 3" / 21.41 m

Beam

20' 2" / 6.15 m

Draft (hull)

3' 9/ 1.14 m

Power
(25-knot +
version)

3 0 0 0 + hp

EURO 2600 FISHING

COCKPIT
VERSION
(12 TO 16 KNOTS):
LOA

85'

LWL

77 1 / 23.50 m

0/26.00

in

Beam

20' 3'/ 6.17 m

Draft (hull)

3' 9/ 1.14 m

Power
(16-knot
version)

700-2,000

hp

60

Chapter Six

Due to the n u m b e r of questions we receive

on the subject of s p e e d versus i n s t a l l e d h o r s e power, it is apparent that m a n y of y o u m a y wish
to learn m o r e a b o u t this subject. I r e c o m m e n d
checking' out o u r e - b o o k Choosing a Cruising
Powerboat. This e - b o o k on C D - R O M w i l l go a
long way to a n s w e r i n g m a n y of y o u r q u e s t i o n s ,
i n c l u d i n g some that y o u w e r e not a w a r e n e e d e d
answering.
All of o u r p o w e r b o a t s i n c l u d i n g the E u r o
range are d e s i g n e d in accordance w i t h G e r m a n isher Lloyd for C a t e g o r y 1 (unrestricted cruising
a r e a ) , w h i c h is s u p e r i o r to m o s t of the o t h e r
s o c i e t y r u l e s such a s E U C E - A r e q u i r e m e n t s .
T h e s e are truly o c e a n g o i n g vessels.

Voyager Trawler Yacht Series

My interest in trawlers goes back to my time
spent as a y o u n g naval r a t i n g in the R o y a l A u s tralian Navy. I w o u l d often observe c o m m e r c i a l
fishermen out in weather that was more than a little uncomfortable even in our m u c h l a r g e r naval
vessel. These trawlers were very special.
These o b s e r v a t i o n s w e r e to stand me in
good stead when later I designed m a n y c o m m e r cial fishing trawlers built to operate in the r o u g h
conditions off the A u s t r a l i a n coast. T h e s e boats
had to be able to handle all types of wind and sea
conditions and w e r e often r e q u i r e d to cross the

The Trawler Yacht 620 has proven to be one of our most

popular designs in this range. This example, the E m e r a l d
was built in Canada for Tom Springer.

shifting s a n d b a r s that are a feature of the entrances to m a n y Australian ports and harbors. Bec a u s e b u m p i n g over s a n d b a r s i n b o i s t e r o u s sea
conditions and breaking waves was and is a w a y of
life for the boats and the crews w h o fish these areas, commercial trawlers have to be tough. I have
carried the same design p h i l o s o p h y and practice
into our r a n g e of V o y a g e r T r a w l e r Yachts.
A l u m i n u m is also a s u i t a b l e m a t e r i a l for
trawler yachts, especially if y o u have a special case
w h e r e the w e i g h t h a s t o b e k e p t low; t h e n a l u m i n u m i s worth y o u r consideration. M y personal
c h o i c e for an offshore c r u i s i n g p o w e r b o a t is an
a l l - s t e e l vessel. T r a w l e r y a c h t s a r e b y d e s i g n
m e d i u m - d i s p l a c e m e n t v e s s e l s . T h e m o d e s t difference in the a l l - u p w e i g h t b e t w e e n a fiberglass
o r a l u m i n u m t r a w l e r a n d a n a l l - s t e e l o n e can
w o r k in favor of the steel boat.
T h e first of the V o y a g e r T r a w l e r Yacht series
was based on our successful W a v e r u n n e r T r a w l e r
Yacht 4 0 / 4 2 and T r a w l e r Yacht 4 5 . O v e r 3 0 0 of
these boats have been built w o r l d w i d e . T h e u p dated versions of these boats are available as precut steel kits, and the interior can be customized
to suit y o u r particular r e q u i r e m e n t s .
T h e smallest steel trawler y a c h t with a raised
p i l o t h o u s e configuration w h e r e t h e r e i s a c c o m m o d a t i o n u n d e r the pilothouse should be in the
r a n g e of 40 feet. If y o u r e q u i r e a s m a l l e r m e t a l
raised pilothouse vessel, then it will be necessary
to use a l u m i n u m at least for the decks and
superstructure. In that case 32 feet is about
the m i n i m u m size.
Stability is a very important factor with
any trawler yacht design. We subject our designs to extensive c a l c u l a t i o n s that are now
much easier to undertake thanks to the computer software that has b e c o m e available in
r e c e n t y e a r s . Ballast is r e q u i r e d in most
t r a w l e r y a c h t s and e s p e c i a l l y in the s m a l l e r
boats as well as in the long-range versions of
the Voyager Trawler Yacht series.
F o l l o w i n g are just a few of the extensive range of trawler yachts that are available
as kits or cutting files. To see the full r a n g e
of a v a i l a b l e t r a w l e r s , visit w w w . b r u c e
Lady,
roberts.com.

Building from a Precut Kit

61

Building from a Precut Kit

This Trawler Yacht 43B was cut

using our cutting files and built in
Australia.

Note the smooth finish on the stern

of this Trawler Yacht 43 built from
cutting files supplied by our Australian office to a local builder.

Detail like this gives any boat a professional finish. This Trawler Yacht
43 was cut and built in Brazil.

An attractive interior finish on a

Trawler Yacht 43 built in Australia.

63

64

Chapter Six

Here we see the Trawler Yacht 485, side deck version.

VOYAGER TRAWLER
YACHT 485
ALREADY popular, this mid-sized
trawler is ideal for those who want
something a little larger than the
TY43 but that is still affordable for
the average family.

It only takes a couple of days to get a project underway. This aluminum Trawler Yacht 485 was completed in a few months, in time
for the Seattle boat show.

Building from a Precut Kit

This wide saloon aluminum Trawler Yacht 485 was built by Taylor Bay Boats of Seattle, Washington, from cus
tom

cutting files we supplied to suit the customer's requirements.

A view of the Trawler Yacht 485

swim platform,

steps,

and optional

aft engine room access.

65

Chapter Six

VOYAGER TRAWLER YACHT 55

The Trawler Yacht 55 is designed to be built in
steel or aluminum. This boat can be ordered as a
kit, as partially built, or as a complete boat. Several varied accommodation layouts are possible.

This Trawler Yacht 55 was built in Brazil. After initial

sea trials the owner wrote: Last week we arrived
from a 'shakedown

cruise, nonstop, in full sea condi-

tions of 605 miles; we had a good weather window

and the voyage went by without incident. Our average cruise speed was 8.7 knots but don't have the
fuel consumption as yet (think will be close to 21
liters/hr)."

The builder of this Trawler Yacht 55 chose a galley-up layout and still has
adequate room for this comfortable lounging area as well as a dining area
and spacious galley.

Building from a Precut Kit

67

68

Chapter Six

John Springer's Trawler Yacht 620, the E m e r a l d Lady, moored in Annapolis, Maryland, after her delivery cruise
from Nova Scotia, Canada. This is what Tom Springer had to say about his boat: "First day out we were running
in 15-foot seas, the boat handled great, and we got the boat home on the 19th of October. She performed
very well on the trip from Nova Scotia. She is beautiful and we are very pleased with her design."

VOYAGER

TRAWLER YACHT 620

The Voyager 620 has proven to be one

of our most popular kits. Several are already in service worldwide with many
more

currently

under construction

from kits and cutting files. This design

comes in two basic versions; Version A
features side decks completely around
the pilothouse and saloon while Version B has a full-width saloon thus
creating a huge daytime living area.
Both versions are equally popular.
The accommodation below is flexible
and can be arranged in several ways
to suit your requirements.
LOA

62' 0 / 1 9 . 1 0 m

LWL

56' 3/15.93 m

Beam
Draft

18'
6'

2/5.53
0/1.83

Power

250-1,100

Displ.

140,000

m
m

Pictured above is just a small area of the huge engine room in Lee

hp
lb/63,636

Simpson's Trawler Yacht 620B. The headroom at 7+ feet (2+ m)

kg

will appeal to even the tallest owner.

Building from a Precut Kit

A sense of humor is required to build your

own boat! Here we see one of Lee Simpson's assistants considering another use
for the mast from Lee's Trawler Yacht
620B.

Here are some comments from Lee Simpson while

he was building his yacht: "We are really enjoying the
project. I have a friend that comes to work on the boat
in the evening just for the relaxation. We are almost finished welding the hull. We have built the saloon and pilothouse on a jig on the ground andas I must remove
it for transportfeel there are benefits to building it on
the ground. I will lift into place before moving to make
The king-sized berth in Lee Simpson's Trawler

sure everything fits." It did fit and Lee's Trawler Yacht

Yacht 620B.

620B is now on its way to her home port in Alaska.

Version A accommodation

lay-

outs (top). Version B arrangements (bottom) are similar but

feature a full-width saloon.
There is adequate room to
vary the accommodation
suit

your requirements.

to

69

70

Chapter Six

Spray Trawler Yacht Series

The radius-chine Spray Trawler Yacht 475 has a steel hull and aluminum superstructure. The Spray is a wellproven hull type suitable for both sail and power options.

Over the past 30 years several Sprays have been

built as successful trawler yachts and commercial fishing boats.

The radius-chine building technique offers
ideal hull form for serious offshore trawlers.
you

the added attraction of a beautiful round-bilge hull and is an

Combine the Spray with the radius-chine building method and

have something special.

SPRAY RADIUS-CHINE

TRAWLER

YACHT 475

We have recently designed the first of the radius-chine Spray hulls. The plans and cutting files for the Spray
Trawler Yacht

475 were pepared for an experienced trawler owner who knew exactly what he wanted.

In

this case various design considerations required that we combine the steel radius-chine hull and decks with
a marine aluminum superstructure. Although smaller Sprays can be configured as

Trawler Yachts,

we con-

sider 48 feet (14.6 m) the minimum size for serious world voyaging.

The

accommodation

layout

shown

is one of several arrangements that

would be possible within
chine Spray hull.

the radius-

Building from a Precut Kit

SPRAY TRAWLER
YACHT 52 AND SPRAY
TRAWLER YACHT 58
The first Spray Trawler Yacht
52 was designed to U.S. Coast
Guard T boat regulations and
will be used for passenger-carrying charter.

Another version

is being designed for charter

operations in

the Caribbean.

The large flush deck areas

will provide

adequate

stowage

for dinghy and various deck

boxes and other stowage as
required.

The

bulwarks

combined

moderate-size
with

sturdy pipe life rails provide

some security for offshore
cruising.
These designs lend themselves to many different accommodation

arrangements.

The two shown here are for

the Spray TY52 and the larger
Spray TY58. Both versions
feature
room

full standing headthroughout

modation areas.
pilothouse
in

size

the accomThe on-deck

could be

increased

without compromising

the stability of this vessel.

Note that the present A/B
ratio is a very favorable 1.75.
Another possibility in

either

vessel would be to have a

grand saloon aft.

The volumi-

nous engine room is accessible from both forward and aft

accommodation
features

areas

and

full standing head-

room throughout.

There is

adequate room to install a

workbench as well as all of
the

machinery

and

equipment

necessary in a long-distance
passagemaker.

SPRAY 52

SAILBOAT

Kits are available for this full sailboat design. You can also choose
between gaff and Bermuda rigs.

71

72

Chapter Six

SPRAY 58

TRAWLER

YACHT

Kits available for this full sailboat design

include a

choice between gaff and

Bermuda rigs. This new design is now

available as a cut-to-size kit or cutting
files.

Building from a Precut Kit

SPRAY 58 TRAWLER YACHT

The varied designs available lend themselves

to different accommodation arrangements.

For instance,

you

may decide to have the galley in the pilothouse. A grand cabin could be arranged aft of the engine room.
These Spray trawler yachts and sailboats are serious ocean-crossing vessels and are well proven by many
circumnavigations.

74

Chapter Six

SPRAY 460 SAILBOAT A AND

C VERSIONS

This kit was developed from the Spray 45, which

was a stretched version of the Spray 40. When designing this kit we decided to reinstate the correct
Spray beam-length

ratio.

Already several of these

boats have been built and others are under construction in various parts of the world.

The Spray 460A is for those who prefer the aft cockpit/pilothouse combination.
a couple with a child or for occasional guests in the twin-berth cabin.

This is an ideal arrangement for

Building from a Precut Kit

The Spray 460C is a larger version of the Spray

400C. The extra length allows for adding a cockpit
without sacrificing any of the accommodation
below.

The Spray 400C accommodation

layout makes

maximum

use of the available below-deck space.

space

75

76

Chapter Six

SPRAY 400 SAILBOAT A AND

C VERSIONS

The Spray 400 is our kit version of the popular

Spray 40.

Over 500 of these boats have been built

and many have circumnavigated,

gle-handed.

some sailed sin-

This is a great boat and affordable for

the average family who wants to undertake some

serious

offshore cruising.

The Spray 400 Version A can

be fitted with a variety of
rigs. In fact, almost every
possible rig has graced the
Spray over the past

100

years. The fixed dodger is

optionalnot
but

glamorous

very practical.

The

accommodation

plan

shown here has been used

literally hundreds of times in
the Spray 40 hull and has
p r o v e n an attractive and
practical

layout,

However

the space available lends itself to myriad variations so

you can feel free to vary and
change to suit your requirements.

Building from a Precut Kit

The Spray 400C has

been one of our
most

popular de-

signs and hundreds

of these boats are
cruising the oceans
worldwide. This is a
Spray version for
those who like
something

different.

The Spray is a very

well-known

design,

and from personal

experience I can assure you that this
design arouses interest wherever you
sail. You will find
many new friends
worldwide if you
cruise in this boat.

This is a great layout for those who want to gain the most living space possible
in a 40-foot (12.2 m) cruising boat.

78

Chapter Six

This is the Spray 370A with a gaff cutter rig. As mentioned elsewhere, there are a variety of rigs available for
this and other Spray designs.

Building from a Precut Kit

This is the Spray 370B pilothouse version. The accommodation plan shown is only one of several available for this
design.

SPRAY 370 SAILBOAT A,

B, AND C VERSIONS

The kit version of the Spray 370 was developed from the Spray 36 (400-plus sailing worldwide).

The Spray 36

was a stretched version of the Spray 33, but the beam remained the same. Although the Spray 36 was and is
a very popular boat we decided to reinstate the correct Spray beam-length ratio in the kit version. Another
problem with the Spray 36 was that the aft cabin was just a little cramped, so by lengthening the boat to 37
feet combined with the corrected beam ratio,

we have greatly improved the accommodation and the feeling of

space that is so desirable in a cruising sailboat. (Note that the Spray 340, a 34-foot /10.36 m/ version of this kit
or cutting files, is also available.)
Several sail plans are available for the various Spray kits, including Bermuda cutter or ketch; gaff cutter,
ketch, or schooner; and junk rigs for most of these designs.

80

Chapter Six

Building from a Precut Kit

VOYAGER

388

This radius-chine kit

boat is based on our
highly successful
Roberts

370 and

Roberts 392 designs.

Over 200 of these
designs are sailing the
oceans of the world.
The Voyager 388 is
slightly longer than the
R370. We took the opportunity to raise the
cabin roof to give a
greater feeling of spaciousness below. This
design features full
headroom

throughout.

Accommodations

can

be rearranged to suit
the client's needs. All
radius-chine kits supplied by Bruce Roberts
include all the radius
panels bent to exact
shape and ready to fit
in position on the hull.

This Spray 370A was

built from cutting files.
Note the fair hull as
shown with the glossy
paintwork; this fairness
in a steel boat is usually the result of using
a precut kit or cutting
files.

81

82

Chapter Six

VOYAGER

432

This was developed from the Roberts

432/434.

This radius-chine design can be

ordered as a kit or cutting files and can be

rigged as a cutter, ketch, sloop, or staysail
schooner.
sole plus

The V432 design has a single-level

full standing headroom

throughout.

This is the minimum size that will accommodate two master double cabins and still retain
the centerline double berths that are so popular with many cruising liveaboards and especially

suitable where the boat is to be shared

by two couples. If you plan single family use

for this boat

then the alternate accommoda-

tion layout may be preferred. See below for

both

suggested

ments.

accommodation

arrange-

Of course you may have your own

ideas for the perfect layout.

there are several rigs suitable for

the Voyager 432 including cutter
(shown) and ketch.

The boat fea-

tures

contemporary

the Roberts

long keel, which has been well

proven on the Roberts 432 and
other designs.

This layout

features self-contained

accommodation

tor

two

couples.

However several other layouts are

possible to suit the client's particular

requirements.

Building from a Precut Kit

VOYAGER

450

Note that all the Voyager series have high stability numbers that are what you would expect in a serious offshore cruising sailboat. The study plans that are available on CD show all this plus much more information
about the designs. This kit design is a smaller version of the Voyager 495 and embodies the best features of
the popular and well-proven Roberts 434. Already several of these sailboats have been completed from our
kits and cutting files and have lived up to their reputation. Flush deck configuration combined with a pilothouse makes this a great boat for cruising in all areas of the world.

The Voyager 450

can be fitted with
a variety of rigs,
including the cutter
shown

here.

83

84

Chapter Six

Here we see the Roberts contemporary long keel that has proven so popular and successful on many
sailboats over the past few years.

The accommodation plan shown is one of several possible layouts for this

design.
Version A, Long Keel
Right Moments
1/2 L o a d C o n d i t i o n

Heel Angle

(cleg)

Here we see the stability curve for the Voyager 450, which reflects a very satisfactory 136 degrees of positive
stability.

Building from a Precut Kit

VOYAGER

495

This design has all of the features that make a great cruising
boat. The radius-chine kit is simple to assemble. Partially built
and complete boats are also
available. There are a variety of
accommodation

plans

that

can

be used in this versatile radiuschine sailboat.

Long- and short-

keel models are available for this

design.

86

Chapter Six

This is the deck layout on

the Voyager 495 built by
Bernie Loyer in Chile from
Roberts cutting files and
plans.

Here we get a good idea of the size of the huge master aft
cabin in the Voyager 495. I have resided in such a cabin,
and the feeling of spaciousness is equal to that in the best
hotel

rooms.

Here we see one of the many Voyager 495s

that are already in service in Canada, the
United States,

Chile, Australia, the Czech

Republic,

Netherlands,

the

and elsewhere.

Building from a Precut Kit

VOYAGER

542

This kit was developed from the

well-proven Roberts

53 (over

500 in service worldwide

the more recent

and

Roberts 532

(over 200 completed to

date).

Many examples of this design

can be found in service worldwide. The Voyager 542 makes an
ideal charter vessel and several
are already in service in popular
cruising areas.

87

88

Chapter Six

Here we see W e s t e r n
G r a c e , a beautiful example
of the Voyager 542. This
particular boat was built
in Canada and is now
in charter service (full
details available at www.
bruceroberts.com).

In most of the Voyager sailboat series we have

arranged the aft deck so that the cockpit can be

The attractive engine room vents installed on the

arranged in two or three ways to suit the owner's

W e s t e r n G r a c e illustrate how this type of fitting can

preference. Here we see the cockpit as laid out on

add to the beauty and professional appearance of a

the W e s t e r n G r a c e , a Voyager 542.

boat.

Another view of the W e s t e r n G r a c e showing the attractive stern and swim platform.

Building from a Precut Kit

VOYAGER

655

The Voyager 6 5 5 is the kit version

of the very popular New York 6 5 .
The radius-chine kit is easy to
assemble.
models

Long- and short-keel

are

available.

LOA

6 6 ' 9/ 20.34 m

LWL
Beam
Draft
Displ.

6 0 ' 8 / 18.50 m
6"/5.03 m

16'
s

8 0"/2,44 m

80.000

lb/
36,286 kg

Sails

2,025 sq.

ft.I

188 sq. m

89