72’ Power Cat

This project was a 72’ passenger ferry to be operated in Panama. The boat is built to USCG passenger vessel standards, but not certified in the US. Panama has similar rules, however, and following US rules is an easy enough way to comply. This boat has infused E-glass and Corecell foam hulls with infused carbon and foam main decks All other panels and pieces except for the carbon underwing beams are made with wet lay-up E-glass and foam.

Frames for the plug are erected, then planked.


We then glass and putty the plug.


During this time we are also building the underwing beams, roof panels, and deck panels. Here is a picture of the carbon deck panel infusion.


The plug is finished and prepared to make the mold.


Glass is laid up dry, then bagged and infused. This photo shows the epoxy, in green, on its way up towards the next black infusion line.


Legs are glued on and the mold is flipped.


Once the mold is prepped, the glass and foam are then laid inside the mold. Then the infusion materials are added and bagged. Once infused and cured, the hull is removed and positioned where needed.


The hulls are then aligned, fore and aft, up and down, and perfectly parallel. The beams are then glued in, locking the hulls in place.


Once all beams including U/W beams are in place all machinery and tanks are installed.


 The decks are then glued down, with the cabin immediately after.


The pilothouse is then added along with the heads aft.


The fairing and painting process is then begun. The mold is fair enough for the boat to require no fairing on the hull itself, but the tape seams must be feathered in. 

The boat in white.


With stripes, window shading bottom paint and rails added, it is starting to look like a finished product.


During the fairing and painting process, the systems are installed and the electrical begun.


Once paint is complete, the flooring, seats, and windows are installed. This is the main cabin looking forward.


The details finished, ready to move the boat down to the travelift.


Finally, launch day and sea trials!!

Island Express III  Launch

Built with a small crew (averaging 5 total), she was produced in an extremely efficient manner at minimal cost. With two 500hp Iveco engines and jet drives, she cruises at 28 knots. We delivered her in three weeks to her new home at Balboa Yacht Club, Panama. 

Saying goodbye with the Bridge of the Americas in the background.