Tuesday, September 28th Seminars
8:30 a.m. to 10:00 a.m.
Session 101
Designing for Pod Drives
Introduced at the 2005 Miami International Boat Show, Volvo Penta’s IPS quickly established itself as a leading propulsion choice among pleasure-boat owners and builders. Two Volvo competitors, Cummins and ZF, followed suit by bringing more pod-propulsion systems to market. All of these systems offer benefits that include increased efficiency, better performance, nimble handling, and low noise levels. They also offer a user-friendly interface that makes maneuvering easier for less-experienced operators, expanding the range of people who can comfortably drive a good-sized boat. Like all propulsion systems, pods have nuances that must be taken into account when designing or selecting a hull for a pod-drive system. In this seminar, we’ll start by reviewing currently available pod-drive systems. We’ll also consider arrangement and hull-design aspects specific to pod propulsion. And, you’ll hear from builders who have implemented each of the pod-propulsion systems in a production setting. Our goal is to provide you with a clear understanding of what a pod-propulsion system demands in terms of boat design.
Speakers: Jeffrey Bowles (Donald L. Blount and Associates); Adam Rolinski (Tiara Yachts); Fabrizio Loi (Lazzara Yachts)
Session 102
Performance and Quality
Powerboat performance runs the gamut from leisurely non-planing displacement hulls to high-speed pickle-fork catamaran designs with extreme power-to-weight ratios. As performance increases, safety factors typically decrease, and—for the survival of the crew and the boat’s builder—precision engineering and construction become critical. High performance demands high quality, so in this session we’ll closely examine the connection between those criteria. Don’t think our discussion will be restricted to gas-guzzlers, though; high-efficiency “green” boating demands lightweight, highly engineered structures, too.
Speakers: Bruce Pfund (Bruce Pfund/Special Projects LLC); David E. Jones (Revenge Advanced Composites)
Session 103
Materials and Laminate Testing
When should you look for ways to conduct simple tests yourself? When should you rely on your vendors or outside testing services? In this seminar for laminators and managers alike, we’ll offer a variety of solutions to satisfy your need for fast and accurate testing, whether it’s for your shop alone or for a group of builders interested in comparing properties in similar products. We’ll outline the type and level of laminate testing available from product vendors, who often have the expertise to provide the information you seek. For those of you who want to explore in-house testing for specific materials, we’ll also offer examples of minimal equipment, readily obtained or made in-house. You’re welcome to add your own experiences to our mix.
Speakers: Rob Mazza (Baltek Inc.); Dan Naugle (Grady-White Boats); Jeff Wright (Gougeon Brothers Inc.)
Session 104
Tooling for Closed-Molding
Making the switch to closed-molding in a post-recession economy requires a number of changes in the way you work. We’ll discuss how to engineer new tooling for future flexibility. We’ll also show you what some innovative shops are already doing as they compare relative tooling and production costs to aid them in their decision making. We’ll help you decide which tooling will maximize your return—whether you’re producing one, ten, or hundreds of parts. We’ll also consider: how factors such as model changes and complexity of a part affect your tooling choices; how to prepare mold surfaces to take the heat of infusion; and how not to destroy those molds that can’t. Finally, we’ll help you investigate what you can do with your existing molds, and we’ll review how to engineer laborsaving features into specific tools, whether you’re already infusing or just getting ready to make the switch.
Speakers: Chris Duppenthaler (Northwest Yachts); Vic Duppenthaler (OneWorld Consulting)
Session 105
Surveying Metal Hulls
To effectively survey a metal hull, you need a working knowledge of the properties of metals commonly employed in boat construction, as well as of the material mechanics—and the failure modes—of those metals. Additionally, you should be familiar with welding techniques, metal corrosion and wastage, and coating systems. Finally, you must also know appropriate testing techniques, both manual and electronic. In this presentation, we’ll touch on all these topics, focusing on the steel and aluminum alloys most commonly encountered in the field. Just as importantly, we’ll provide you with resources for your own independent study of surveying metal hulls, and we’ll discuss how to obtain relevant information, as well as testing equipment.
Speaker: Ron Reisner (Reisner, McEwen & Associates, Marine Surveyors and Consultants)
[WB] Session 106
Wood/Epoxy Construction With Locally Grown or Indigenous Wood
Wood can be a wonderful engineering material, so you may be puzzled by ads for “wood free” boats. Is a no-wood boat really better? Equally puzzling to our panel is why wooden boat builders do not rely more on an indigenous product. Our panelists also believe it may be time to revisit some age-old material standards in order to encompass modern adhesives. Here, we’ll make the case for building in wood and epoxy, a combination that can take advantage of wood’s properties while minimizing the negative aspects of traditional wooden boat construction. We’ll show you how a wood/epoxy composite addresses the durability issue in a different fashion than you can achieve with traditional methods—and thereby use a less-durable wood. (Consider how widely balsa is employed in today’s boatbuilding!) We’ll discuss the pros and cons of working with materials such as Douglas-fir plywood, cypress, or cedar dimensional stock, along with other locally grown species. We’ll also discuss the effect of moisture content on the mechanical properties of wood, and we’ll describe lamination methods to minimize the effects of flaws in dimensional timber.
Speakers: Craig Blackwell (Blackwell Boatworks); Jamie Houtz (The Landing School); Joe Parker (PRO-SET Inc.)
[ABYC] Session 107
Electric-Powering Options
As energy and environmental awareness increase in the marine industry, it’s no surprise that boatbuilders and their customers are seeking more-efficient, less-polluting systems. In this session, we’ll look at the special factors that electric-power installers need to consider. We’ll start with a discussion of weight balance and placement of hybrid components; then we’ll cover such details as generator kW and battery pack kWh sizing, hotel-load planning (converters/inverters), propellers and propeller sizing, renewable inputs, energy-management techniques, and regeneration. We’ll also explain the specifics of motor technologies and considerations, controller technologies and considerations, and advanced battery chemistry. We’ll close with a comparison of electric power in sail- and powerboats, and offer some guidelines for electric power safety and education.
Speakers: Eric Sponberg (Sponberg Yacht Design Inc.); Dave Tether (Electric Marine Propulsion LLC)
[ABYC] Session 108
Networking Marine Electrical and Electronic Systems
Onboard electrical and electronic products have traditionally worked independently of each other, but during the past several years, key companies have built communications networks that allow those units to speak a common language. Networked systems offer simpler installation, improved efficiency, greater flexibility in system design, and—significantly—ease of operation for the end user. The result provides operators with all the desired systems information when, where, and how they want it. Here, we’ll compare the pros and cons of the various networks. How do these systems affect the boatbuilding process? What do builders, repairers, and technicians need to know to maximize the value of these systems? We’ll answer your networking questions and discuss methods and techniques for integrating electronics and electricals into one comprehensive system.
Speakers: Ely Bates (Navico); Menno Ligterink (Mastervolt Inc.)
[ABBRA] Session 109
Liability Protection for Boatyards and Marinas
When money is tight, do you let your compliance efforts slip? The message in this seminar is that you must do just the opposite. When times are tough, you need to protect your facility from liability more than ever. For example, five years ago you may have been able to afford fines or pay to defend yourself in a lawsuit. That attitude today might be the final straw that breaks your company financially, not to mention what may happen to your credibility in an era in which savvy customers expect you to be in compliance with environmental, health, and safety regulations. A commitment to compliance can help protect you when legal problems arise from regulators as well as from your customers, subcontractors, boat crews, and even your own employees (your biggest asset and your greatest liability). Best compliance-management practices can save you time and money while your business improves both in productivity and quality. Attend this seminar to learn the steps toward creating a workplace that is resistant to lawsuits, socially responsible, profitable, and home to a work force made up of safety-conscious, healthy employees.
Speaker: Kellie Thornell-Crete (Ink Inc.)
[MITEC] Session 110
Marine Training from a Shipbuilding Perspective
Work-force development programs and training resources are now being established for the recreational boat building-and-repair industry. Among shipbuilders, though, job descriptions, career ladders, skill sets, and other benchmarks of successful training and work-force development have long been in place. What can we learn from the shipbuilding industry about growing our work force and creating an atmosphere of career and industry awareness? Join us to discuss the differences and similarities in how our two industries approach the task of recruiting, training, and sustaining a competitive labor base.
Speakers: Rich Difede (Gold Coast Yachts); Byron Dunn (Gulf States Shipbuilders Consortium)
[NMMA] Session 111
A Quality Assurance Checklist for Meeting EU Requirements
One definition of quality is to have a “product free of deficiencies,” but another is “conformance to requirements.” In Europe, basic requirements for boat construction are laid down in “directives,” including the “Recreational Craft Directive,” or RCD. Since compliance with the applicable CE directives is obligatory, a boat manufacturer may turn to a quality assurance system that meets several targets, such as: satisfying customer demands; building a boat free of deficiencies in accordance with requirements; documenting the manufacturing process and compliance of the boat in case of a legal action; and competing in the marketplace through continuous improvement of the product. In this presentation, we’ll consider approaches for verifying the added value of such a system, and explain how you can compare that value with emerging costs. We’ll start by showing you how to identify critical points and allocate them to the right department and/or production step, working from International Marine Certification Institute checklists. We’ll also show you how to integrate these free tools into your own quality system. In addition, we’ll cover IMCI’s Guided Application System, and explain how GAS will help save you time and effort by readily providing the information you need on the RCD, ISO standards, and their related documents when you’re building a boat for the European market.
Speakers: Tom Marhevko (National Marine Manufacturers Association); Alexander Schlosser (International Marine Certification Institute)
[IBEX] Session 112
Consultive Selling
In this seminar, you’ll learn how to enhance your service department’s selling skills, starting with a process designed to engage your customers and build your relationship with them. Focusing on maintenance sales, we’ll explain the concept of consultive selling and describe how to manage your own workday to improve your customers’ experience during a service procedure. Finally, we’ll show you how to implement a “customer handling system” so that: work is done correctly and on time; your service writers present themselves as courteous professionals; and your communications with your customer are proactive.
Speaker: Rich Guthrie (Five Star Solutions LLC)
3:30 p.m. to 5:00 p.m.
Session 201
Diesel Fuel Tank Design and Installation
In this session aimed at mechanics and supervisors, we’ll explain precisely how to design a diesel fuel tank that will provide your customers with reliable and long-lasting service, as well as being easier to maintain than most existing tanks. You’ll learn how to avoid building common faults and flaws into your tank design-and-installation procedure. Since even the best-built tanks fail to deliver reliable, long-lasting service unless properly installed, we’ll troubleshoot those critical steps and outline tank-installation best practices. Finally, we’ll open up the discussion to include a full range of topics such as tank materials, installation methods, inspection ports, stripper tubes, bottom and top feeding, coatings—plus the questions that you bring to the session.
Speaker: Steve D’Antonio (Steve D’Antonio Marine Consulting)
Session 202
Improved Standards for Offshore Sportfishermen
Although ABYC and ISO standards do affect design and construction for sportfishermen, these vessels have a number of specific design features that are not covered by traditional standards or guidelines. For example, excessive wetness and sprayback affect the operation of production and custom sportfishermen alike, especially in rough weather. How can that be resolved in a uniform manner? A more serious topic is the “station-wagon effect,” which fills the cockpit with fumes, including carbon monoxide. Sportfishermen can also have noise and vibration problems stemming from excessive propeller vibration, minimal insulation, minimal exhaust silencing, or air intake location. Could these concerns be improved by standards? What about reducing pitch-and-roll motions and accelerations when the boat is operating at planing speeds? Should commercially available active trim-tab and interceptor systems be covered by standards? We also wonder about the application of gyro stabilizers to reduce motions at low speeds. Join us in this discussion of sportfisherman design concerns, with a special focus on where standards already come into play, and where they should.
Speakers: Jeffrey Bowles (Donald L. Blount and Associates); Lou Codega (Naval Architect)
Session 203
Infusion Conversion: A Case Study
Here, we’ll share a story about building a megayacht with a crew that had never infused anything—let alone a 124’ (37.8m) hull. From this and other closed-molding case studies, we’ll provide you with valuable insights about what it takes for a conversion to be successful, as well as how to work with the latest communication tools to track and stay on top of the project. Our speakers from SP-High Modulus and GRPguru have worked with a diverse array of builders during the past 10 years. Their clients have included the very sophisticated and the very basic, the top yacht builders in the United States and New Zealand as well as boatshops in emerging countries. These speakers claim they have even converted some die-hard pre-preggers along the way. Because of their broad experience, they know that few builders would gladly disclose their learning curve and their bad experiences, so names and places will be changed to provide you with a “parallel universe” for our examples.
Speakers: Andre Cocquyt (GRPguru.com); Richard Downs-Honey (SP-High Modulus)
Session 204
Converting to Low-Styrene Gelcoat
In this seminar, we’ll tell you how the switch to low-styrene gelcoats was accomplished by two major boatbuilders: Tiara Yachts (Holland, Michigan) and Regulator Marine (Edenton, North Carolina). We’ll describe the concerns and problems that each of these companies had to consider. You’ll also hear a different perspective on converting to low-styrene gelcoats from a gelcoat manufacturer. We’ll cover the initial mindset you must have to make the switch successfully, and we’ll look at optimal equipment changes, application adjustments, and shop environment. We’ll also consider specifics such as retraining experienced gelcoat operators, laminating on the newly gelcoated surface, and repairing low-styrene gelcoat. Finally, we’ll review formulations, storage, materials preparation, and handling.
Speakers: Willis Jerome (Tiara Yachts); Noel Searles (Ferro Corporation); Rebecca Wooley (Regulator Marine)
Session 205
Case Study: Structural Repair of a Large Composite Sailing Yacht
Originally built by Windship-Trident in 1992, Cinderella II recently emerged from an innovative and comprehensive structural bottom repair, undertaken to rectify severe water ingression into the sandwich structure. Here, we’ll outline the steps involved in repairing this impressive vessel, starting with damage assessment and continuing through the project’s supervision and completion. We’ll provide key details of the surveyor’s advanced non-destructive examination techniques such as infrared thermography and laser shearography. We’ll also give you an inside look at every critical phase of the project, and share how the parties involved in this major repair successfully completed the specifications of their complex contract.
Speaker: Roby Scalvani (Marine Survey Bureau)
[WB] Session 206
Metal Meets Wood: Custom Hardware
With a modest investment in equipment and basic materials, your custom boat shop can fabricate many types of intricate and distinctive hardware, including bow rails, stanchions, chainplates, shaft struts, gooseneck fittings, and more. In this seminar, we’ll examine the processes of marking, cutting, drilling, and bending of sheet, tube, bar, and rod stock. We’ll then examine the basic joining processes of MIG welding, silver soldering, and gas welding/brazing. Finally, we’ll show you the processes required to give your workpiece a fine finish. While our emphasis will be on bronze hardware, the processes we cover will apply to a variety of marine alloys.
Speaker: Brion Rieff (Brion Rieff Boat Builder)
[ABYC] Session 207
Optimizing Generator Operation
Generator operation on boats is almost always incredibly inefficient. Here, we’ll explain why this is so, based on Victron Energy’s extensive testing of 19 popular off-the-shelf AC generators. Professional BoatBuilder magazine’s contributing editor Nigel Calder participated in this test program, and he’ll share the conclusions drawn from a mass of revealing data on the performance of different types and makes of generators. Join us to learn the study’s findings and their implications in terms of optimizing generator performance on boats. We’ll provide you with a good understanding of the best operating environment for generators, and we’ll describe a number of mechanisms that can radically improve their efficiency and—in many cases—dramatically reduce running hours.
Speaker: Nigel Calder (Calder Enterprises)
[ABYC] Session 208
Drivetrain Design and Specification
If you need to evaluate and specify propulsion gear, this seminar will start you out on drivetrain components, from transmission to propeller. Our focus will be on the factors that result in proper drivetrain selection. We’ll begin with the basics, including propeller blade area or disc area ratio (definition, importance, and application); minimum diameter and blade area; induced drag and tip noise; number of blades, and curing prop noise; propeller tunnel and pocket noise issues; pocket proportions; propeller struts and pockets; and propeller shaft diameter and shaft material. Next, we’ll cover propeller shaft bearings and bearing spacing; shaft overhang; shaft whirling vibration; propeller struts, configuration, dimensions and design, and attachment. Continuing, we’ll cover water inflow to the propeller; constant-velocity joints and universal joints; thrust loads; engine mounts and thrust couplings; and traditional retracting propeller shafts. We’ll close with a discussion of stuffing boxes and stuffing-box water injection; plus engine beds and engine mounts. This will be a very technical session, one that will lay the groundwork for even more detail in Session 308, Propeller and Shaft Sizing; but each of these seminars is designed to stand alone.
Speaker: Dave Gerr (Westlawn Institute of Marine Technology)
[ABBRA] Session 209
Identifying Marine Electric Shock Hazards
This seminar will provide you with a fundamental understanding of electric shock hazards in the marine environment. We’ll examine testing and troubleshooting techniques that identify shock hazards. We’ll start by presenting basic electrical principles, including the need for—and importance of—grounding and bonding systems. Our discussion will cover both hypothetical and real-world scenarios, describing electrical conditions on boats and docks. These case studies will help you understand the nature of hazardous situations as we cover basic procedures for working with common electrical equipment. Whether you’re a technician, surveyor, boatbuilder, engineer, or insurance adjuster, you should attend this session to increase your awareness of shock hazards, going well beyond a basic knowledge of electrical principles. We’ll also target the sections of NFPA 303: Fire Protection Standard for Marinas and Boatyards that are of special interest to marina and boatyard personnel.
Speaker: David Rifkin (Quality Marine Services LLC)
[MITEC] Session 210
Work-Force Development 2010
The marine industry’s work force is built around a huge variety of skills and trades. How do you find and retain the best laminators, painters, mechanics, welders, carpenters, technicians, and managers for your operation? Here, we’ll discuss proven methods and resources for designing and implementing a work-force building plan to provide you with the career-oriented, skilled people you need. To help you keep your incumbent workers with you, we’ll look at new trends and innovative programs, including on-site training, diversification of activities, and community interaction. Finally, since economics are key to any work-force development program, we’ll share some ways to mitigate the costs of developing a core group of skilled, ready, and available employees.
Speakers: Rich Difede (Gold Coast Yachts); Steve Kitchin (New England Institute of Technology)
[NMMA] Session 211/212
Boat Fuel Systems
How can boatbuilders redesign their fuel systems to comply with new emission requirements from the Environmental Protection Agency and the California Air Resources Board? Boatbuilders and fuel-system component manufacturers alike need to have a clear understanding of newly approved administrative procedures and engineering guidelines. Join us for an overview of these regulations, including the design changes being specified for boat fuel systems. For example, the EPA now requires that boats equipped with fuel tanks that are subject to diurnal or permeation emission standards must be designed and built so the boat’s operator can—within reason—fill the fuel tank without spit back or spillage during refueling. ABYC’s H-24 Gasoline Fuel Systems committee is already working to develop a standard requiring boatbuilders to take measures to prevent spillage during refueling; we’ll present information on this change. Finally, we’ll also touch on some of the issues surrounding ethanol, including the status of the “Growth Energy” ethanol waiver.
Speakers: John Adey (American Boat & Yacht Council); George Bellwoar (Perko); John McKnight (National Marine Manufacturers Association); Sean Whelan (Attwood Marine)
