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The construction method of the
Prowler Series originates with two very complex articulating major molds
that make up the majority of the yacht's FRP parts. This exotic tooling
allows the complete hull with its graceful tumblehome aft and built-in
guard rails to emerge as a unit from the hull mold, while the elaborate
superstructure mold encompasses the built-in engine boxes, built-in
ventilation system, window and door recesses, cleat locations, hidden
windlass and rope locker, cockpit and interior cockpit liner and
numerous other features that are normally added on after the primary
molding is completed due to the complexity of designing a tool that
would allow removal in one component. |
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The contrasting non-skid colors, the
texture of which mimics the tentacles on the underside of an octopus and
provides sure footing, is embossed in the deck upon release from the master mold.
The decision to invest in this far more costly tooling requires a degree of
confidence in the ultimate success of the end product and is not for the faint
of heart. Once the decision is made however, it becomes an annuity, paying the
investor back handsomely each and every time a part is constructed through fewer
warranty issues and a greater strength.
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The interior cockpit, cowling,
seating, hatches, engine boxes, etc., emerge as units from the complex
superstructure mold and allow the yacht to emerge far more "complete"
from the tooling after cure. By thoughtful design, this leaves only the
hardtop to be mounted on the molded in FRP windshield framing producing
a yacht that appears as a completed unit, yet only three parts comprise
this elaborate structure. |
Resins from the Epoxy family are infused,
using our proprietary Full Stack Infusion©
method, into Carbon, Kevlar and
specifically engineered biaxial fabrics to produce a monocoque structure free of
rattles and leaks that a yacht with the speed capability of the Prowler may fall
victim to as years pass. No common woven rovings to build thickness are ever
considered due to their absorption of excess resin and reduced strength. The
resins and their catalyzation process, which is proprietary, "bake” the infused
laminate at temperatures approaching two hundred degrees Fahrenheit, while still
in the master mold. This elevated temperature baking precludes post cure, often
caused by subjecting dark colored hulls to extreme temperatures in the tropics.
It is common for ordinary laminates to re-catalyze when subjected to temperatures
greater than that which the original catalyzation process created. Without
the confining structure of the master female mold, a heavily distorted hull with
"print through" of the underlying reinforcements is the unavoidable result.
Since a dark blue, green or black hull in
South Florida will see temperatures of 160-170 degrees F in the summer months,
one must either cure the structure at temperatures beyond that which may be
encountered or be willing to endure the distorted surfaces that will appear. We
are not willing to accept this cosmetic flaw so often seen.
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The beautiful interior woods and cabinetry appear
to be fine furniture of solid wood when in fact they are grain-matched
veneers over foam and Corecell©. The underlying structure of the lovely cabinetry is strong enough for a 250 pound human to sit upon without distortion yet weighs less than 1/2 pound per square foot. Were it to be made of common plywood, covered with wood sheathing, as is the industry standard, the weight would be more than triple that with considerably less strength. The underlying reinforcement panel resembles plastic soda straws, stacked and glued together to form honeycomb cells. These cells are cut to the thickness required and covered on all sides with lovely grain matched veneers of Andes Cherry, Burmese Teak or American Maple. The compressive strength is most impressive.
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Prowler Classic Cabin |
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Prowler Open Cabin |
Corner
posts and door faces are selected from one original log and processed in our
own mill for their unique look. Whereas the paneling that covers the
honeycomb or foam bulkheads is selected for its uniformly matching grain,
corner posts and other highlight area are selected purposely for their
"wild" grain, adding beauty without overpowering the lovely soft hued grains
of the large surfaces. These wild grains from nature are the result
primarily of a period of distress in the life of the tree from which they
came - perhaps a windstorm that caused a broken limb or the competition for
available sunlight in the forest. Carefully selected and placed, they are as
if one chose an object of art to enhance an already beautiful lady.
 The seamless teak and holly sole covers a high pressure foam and fiberglass sandwich as opposed to wood, providing longevity, strength and dimensional stability that plywood cannot approach. In fact, all bulkheads and floors in the Prowler are manufactured on large tables under enormous pressure as resin is infused in precise volume,
in lieu of the normal lay-up method of mops and rollers.
Fine
English beveled mirrors grace doors and cabinets secured by Schwepper Germany door hardware as precise as a fine watch. Grohe Infinity faucets, showers and bath hardware are fitted to compliment the cabinetry throughout. Grohe warrants their Infinity line (their very best) forever, as the name implies.
From
the first drop of resin to the final stainless steel trim, these yachts
are created and constructed one by one, by hand, by artists and
craftsmen who are working in a harmonious sequence to produce a work of
art that will overwhelmingly reassure you of your choice of a
Marlow Prowler.
      
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