Projects

A selection of recent composite boat building, repairs, and refits completed across the Sunshine Coast and South East Queensland.

Marine Composite Construction

Structural Build Process

Composite structural fit-out completed on a 55ft carbon catamaran, including bulkheads, hatch installations, and internal bonding work.

A collage of six images showing the construction process of a custom boat, specifically a catamaran. The images include top side assembly, bulkhead assembly, hull demould and cradle, interior structural fitout, and other stages. The process emphasizes precision assembly and high standards.

  • Structural bulkheads

  • Composite bonding

  • Hatch installations

  • Internal fit-out

Scope of Work

Built to engineered specifications with a focus on structural integrity and long-term performance.

Compilation of images showing the process of installing a custom composite staircase. The images include a rough cut of the stair structure, dry fit and set out, structural bonding, installation process, carbon laminate detail, penetration readiness, and final assembly with structural ties. The setup aims for a clean, durable finish.

Custom staircase installation completed as part of the structural fit-out on this composite catamaran.


Each step was precision positioned, bonded and laminated to engineering specifications, ensuring long-term strength, durability and a clean integrated finish.

Structural Stair Installation – Catamaran

  • Layout and positioning of structural stair treads

  • Preparation and surface conditioning for secondary bonding

  • Bonding of steps using structural adhesive system

  • Filleting and composite taping to engineering specifications

  • Integration into surrounding hull structure

  • Final fairing and preparation for finish stages

Scope of Work

Under Floor Plumbing & Penetrations – Catamaran

Custom under floor plumbing and composite penetrations completed.

This stage includes grey water drainage, bulkhead penetrations, underfloor plumbing fitout, and integrated shower sump installation. All sealed and bonded for a strong, watertight, long-lasting result.

Images showing plumbing and sealing work underneath a floor, including a pipe opening, insulation foam, a body block, and sealing materials for waterproofing.

Scope of Work:

  • Bulkhead penetration reinforcement

  • Grey water drainage system installation

  • Underfloor plumbing layout and routing

  • Shower sump integration

  • Composite sealing and bonding

Vacuum infused composite panels engineered for maximum strength, reduced weight, and consistent resin control throughout the laminate process.

Epoxy Resin Infusion

A promotional image for epoxy resin infusion technology, showcasing several stages of the manufacturing process in a workshop. The image features a diagram with key benefits: maximum strength, no air in the laminate, and 100% resin ratio control, alongside photos of workers preparing and assembling fiberglass molds with resin tubes and infusion systems.

Scope of Work

  • Epoxy resin infusion setup

  • Vacuum bagging and laminate preparation

  • Resin feed and vacuum line installation

  • Composite panel manufacturing

  • Structural laminate consolidation

  • Precision resin-to-fibre ratio control

  • Lightweight high-strength composite construction

Composite Parts & Moulds

Custom composite parts and moulds manufactured for vessel modifications.

This process includes mould preparation, gelcoat application, composite layup, and final demoulding. Delivering strong, precise, and durable components built for marine environments.

A collage showing the process of making custom composite parts and molds. It includes images of composite molds, L-shaped mold, finished composite part, mold layup, mold prep and gelcoat, and demolding. The workspace appears industrial and organized, emphasizing strength, precision, and durability in the manufacturing process.

Scope of Work:

  • Composite mould fabrication

  • Gelcoat preparation and application

  • Carbon and fibreglass layup

  • Structural part manufacturing

  • Precision demoulding and finishing

Custom Composite Work & Alterations

Bow Thruster Installation

Structural Composite Integration

Installation of a bow-thruster tunnel into an existing composite hull, completed as part of a major vessel refit.

The process involved accurately positioning the thruster, creating the hull penetrations and fitting the composite tunnel before structurally laminating it into the surrounding hull. The external profile was then faired, sealed and epoxy primed before final assembly of the thruster unit.

The completed installation provides a strong, clean and fully integrated result designed for reliable operation and long-term service.

Step-by-step process of installing a bow thruster on a boat, including pilot hole drilling, hull penetration, composite tunnel bonding, fairing and profiling, applying epoxy primer, and final assembly with the propeller.
Collage of custom carbon fiber cup holder installation process, showing components, finished detail, installation during work, and practical usage.

Clean, integrated carbon fibre cup holders built into the helm station for durability and everyday usability.

Custom Fitout – Helm Cup Holder Installation

Scope of Work

  • Custom layout and positioning within helm station

  • Precision cut-outs and integration into existing structure

  • Bonding and composite finishing for durability

  • Clean alignment with helm controls and surrounding surfaces

Topcoat Finish Alteration

Following the original carbon-fibre installation, the custom cup holders were faired and refinished in white topcoat to create a clean, seamless finish that integrates with the surrounding helm structure.

Comparison of carbon fiber cup holders before and after being finished with white topcoat, showing exposed carbon, just faired and prepared, and finished detail with white topcoat finish.

Custom Moulded Keel Guard

Composite Protection Built to Fit

A custom composite keel guard was produced to protect the vulnerable keel area where a standard adhesive-backed product was unsuitable for the hull’s tight radiuses and changing profile.

The component was moulded directly to match the existing hull shape, released and trimmed before being permanently bonded into position. The completed guard provides a strong, clean and durable sacrificial layer while retaining the vessel’s original keel profile.

A step-by-step collage of the process of creating a custom molded keel guard for a boat, including mold production, mold release and trim, bonding of the molded component, finished detail, finished profile, and completed installation.

Fit-Outs & Refits

Thermo-Lite Composite Deck Replacement

Lightweight, Rot-Proof Decking Solution

The vessel’s original plywood deck had suffered extensive water damage and deterioration, leaving it unsuitable for continued use.

The damaged flooring was removed and replaced with a custom-fitted Thermo-Lite composite deck system. Each panel and access hatch was accurately shaped to suit the existing layout, finished in marine carpet and securely installed around the helm, seating and onboard fittings.

The completed deck provides a strong, lightweight and permanently rot-resistant replacement while maintaining full access to the vessel’s existing storage and service areas.

Scope of Works

  • Inspection of the existing deck structure

  • Removal of rotten plywood decking

  • Existing layout and hatch templating

  • Fabrication of Thermo-Lite composite deck panels

  • Custom fabrication of removable access hatches

  • Panel fitting and alignment

  • Marine-carpet installation

  • Reinstallation of deck hardware and fittings

  • Final fitment, inspection and clean-up

Series of images showing the process of replacing rotten plywood decking on a boat with a durable, lightweight thermo-lite composite deck, from removing old decking to the completed installation and port-side view.

Repairs & Custom Alterations

Repair/Alteration - Rudder Tube & Bearing Replacement

Replacement of existing rudder tubes with a fully integrated rudder bearing system, delivering smooth, precise steering and long-term reliability.

A collage of images showing the process of rudder tube and bearing replacement for offshore vessel. The main image shows a finished installation with a white rudder tube and blue piping. The smaller images include access and removal of the old component, precision setup with a tool on a table, composite reinforcement on the rudder tube, a structural bond around the base of the rudder, and an internal view of the hollow rudder tube. Text descriptions highlight steps such as access and removal, precision setup, composite reinforcement, structural bonding, and finished installation. Additional text explains the goals of structural repair, alignment, reinforcement, and long-term reliability.

Scope of Work:

  • Removal of existing rudder tubes and bearings

  • Access cut and preparation of surrounding structure

  • Precision alignment setup for new rudder system

  • Installation of new rudder tubes and bearing housings

  • Structural composite bonding and reinforcement

  • Sealing and finishing for long-term durability

Fibreglass Boarding Step Repair

Structural Repair and Gelcoat Restoration

The vessel’s boarding step had suffered significant impact damage, resulting in cracked laminate, exposed internal structure and loss of strength through the surrounding area.

The damaged section was ground back to sound laminate before being structurally rebuilt and reinforced with new fibreglass. The original step profile was then restored through detailed fairing and finished in colour-matched gelcoat for a strong, clean and fully integrated repair.

Sequence of images showing the repair process of a fiberglass boat's boarding step, from original damage to finished gelcoat repair.

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