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.

 

 

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, 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 recatalyze when subjected to temperatures greater than that which the original catalyzation process created and 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.

Marlow/Norsemen Soar Ahead in Infusion Technology

Marlow/Norsemen, working in their own in house testing facility has designed, developed, perfected and implemented yet another stunning advance in state of the art yacht building.

Marlow/Norsemen have developed the Full Stack Infusion© process for the complete hull or any component in the yacht manufacturing process, eliminating the possibility of contamination in secondary bonding processes in the important structures. In the majority of failures found in frp products, the cause is traced to difficulties encountered in the secondary laminating process. Secondary laminating is described as laminating over a cured surface previously laminated. By infusing the entire hull numerous secondary processes are eliminated. This exciting new development allows the entire structure to be infused, from outer skin coat, through coring to inner skin in one shot infusion. Moreover, Full Stack Infusion© saves significant weight. in an average yacht, while providing far greater strength than could ever be achieved using common methods.

It is believed that this is a first in Infusion Technology, other than on very small parts such as lids, hatches, etc. In so doing, secondary lamination operations that risk contamination are eliminated, resulting in a textbook perfect laminate of far greater strength than could be achieved by any other method currently known.

Marlow/Norsemen has, since Hull Number 1, produced yachts using their own proprietary and advanced methods, developed in house and working with such industry titans as Corecel, DuPont, Swancor, Cook, and other industry leaders. Beginning in 2000 with highly advanced vacuum bagging techniques utilizing elaborately designed and developed tooling far beyond the industry norm, Marlow has continuously moved the bar ever higher in every area of fine yacht building.