Longest post in the history of WW right here.
Psyclone, didn't that 61% less fuel and 1/4 the maintenance boat pull up stakes and go out of business??
Also heard the engine didn't have enough tourqe?
Ok here it is MC has how they build their boats step by step. Malibu doesn't really have that on their website. I copy and pasted what Malibu has. It would be nice to know how BU does their floor and gelcoat and what they do with their molds. I couldn't find anything on that though. Maybe some can find it because I couldn't.
Both are right from the websites...
After a prototype boat is validated, molds must be cast of its hull, floor liner and deck. These molds are precisely constructed and then wrapped in a steel skeleton to keep them from warping or twisting over time. We design and build our molds right here at the factory.
Your MasterCraft is only as good as its mold, which must be meticulously maintained. MasterCraft is the only inboard-boat builder with an entire department dedicated to inspecting, maintaining and waxing every mold. Hulls are waxed and buffed every 3 uses, decks every 5. After 50 uses, both hull and deck molds are removed from rotation and undergo a complete overhaul, all to make them a better fit for your boat.
Each MasterCraft deck and hull is prepped and taped off before the gelcoat stage. Tape is applied to the deck to mark where the accent lines will be sprayed after the boat receives the base color.
Boats are built from the outside in, so the first material applied to a boat mold is the color or "gelcoat." Our gelcoat is a product of Cook Composites & Polymers — the number-one gelcoat producer in the world.
To get multiple colors on the exterior of a boat, we carefully apply layers of paper and tape to the mold, spray it with gelcoat and then remove the tape. The gelcoat is sprayed 22 millimeters thick and checked to .005 inch. Each mold is striped and gelcoated up to 3 times to give every MasterCraft a rich, colorful finish. MasterCraft even goes so far as to gelcoat the liner. This is day one. It takes approximately 7 business days to build a boat.
Think of it as gelcoat insurance. A protective layer of resin is applied between the gelcoat and the first layer of fiberglass to prevent gelcoat print-through and blistering. MasterCraft is one of the very few boatbuilders who currently use this preventive measure to ensure the long-term beauty of your boat. We wouldn't have it any other way.
Now your boat is ready for the first application of fiberglass. We start by wetting the mold with resin, laying in a blanket piece of fiberglass, saturating it with more resin and then hand-rolling every crevice to remove air pockets. This application is referred to as the "skin" stage.
The preferred way of constructing a boat is to hand-lay the fiberglass. Handlaid fiberglass is stronger and more consistent. That's why we buy premier-quality mat and woven fiberglass and then cut it into the appropriate shape and thickness of each individual model boat. We hand-lay up to 22 layers of fiberglass on each boat to ensure strength.
Next, a layer of stiff synthetic foam is applied to the boat for a superior strength-to-weight ratio. Our synthetic foam is the most advanced product available today. It is lighter, stronger and more durable. It also serves as a heat barrier, a cosmetic print-through protector and a stiffening agent.
Stringers are the backbone of your boat. MasterCraft's exclusive Monocoque stringer system is primary-bonded to the hull. AnchorLok™ aluminum, steel and high-density polyethylene (HDPE) pieces are glassed into the structure for anchoring major external hardware.
Steel for engine and ski-pylon mounting is sandwiched under the liner. PVC conduit is laminated into the deck for easy cable and wire routing.
While some manufacturers send out for parts, we handcraft even small fiberglass parts, using the superior handlaid method, to ensure quality and the LifeMaster® construction seal of approval. Ski lockers, coolers, trailer fenders and other pieces are built on a specially allocated assembly line.
The MasterCraft liner system is unequaled by any other inboard company. The mechanical bond and unibody construction adds rigidity and strength, making a MasterCraft more like offshore fishing and performance boats.
After the floor liner has been separated from the mold, it's sanded and prepared for installation. While the hull is still in the mold, the floor liner is lowered in and bonded with a vinylester adhesive in a process called GlassLok.® Then a 1-ton press is lowered into the hull and ratcheted down to hold the floor firmly in place. The end result is a handlaid fiberglass liner that works as a floor and guarantees the hull's strength and shape over time.
While the press sandwiches the 2 unibody pieces together, MasterCraftsmen inject expanding closed-cell flotation foam in the open cavity between the hull and floor. This ensures level flotation, and noise and vibration dampening.
After the hull lamination is complete, it's time to remove it from the mold. Using special tools, workers chisel around the boat's edges to free it and then attach hoists to gently lift it out. This birthing process is remarkable considering the deep lustre of the gelcoat and the crispness of the hand-striped accent lines.
After the hull is separated from the mold, the deck is separated in a similar process. Then drillers and grinders, donning climate-controlled space suits and shielded helmets, go to work trimming rough fiberglass edges and precisely drilling holes where parts will be attached in assembly. MasterCraftsmen secure color-coded jigs around the boat, carefully drilling each hole Every boat has its own set of jigs to ensure that no hole is mistakenly placed. Each boat will be drilled with 100 to 200 holes at this time. This type of tooling allows MasterCraft to produce a high-quality product with superior fit and finish.
Our quality control managers and supervisors methodically check, inspect and report on every boat that comes down the line. While there are QA checkpoints throughout the lamination building, no boat is allowed to move into assembly without passing a stringent final inspection. At this QA station, the trained eyes of our quality personnel scour the hull, deck and liner with light wands to catch minute imperfections. Then they join the hull and deck to ensure that the shoebox fit is secure.
Over 1,000 components are installed on 17 different model boats, at 15 stations, along 3 separate manufacturing lines. Everything from dash pods to engines to stereos and cleats is installed here with utmost precision and attention to detail. At this point the boat is only 2 1/2 days away from completion. One manufacturing line is dedicated to direct-drive boats and another line is dedicated to VectorDrive™ boats. Each of these lines runs the full length of the building, and a separate line, running half the length of the building, is dedicated to the production of the MariStar 280 VLD and the X-80 due to their size.
We compression-mold our ProStar dash and glove-box lid to eliminate any squeaks, rattles and blisters. MariStar dashes, glove-box lids and armrests are vacuum-formed parts. All instrument and stereo remote control panels are made of machined billet aluminum. The Teleflex® Xtreme cables reduce loss of motion up to 70 percent
We use high-quality Duetche® connectors on all bilge wiring to ensure a positive connection and withstand the elements of the marine environment. Borg-Warner™ provides electromechanical gauges for more responsive electronics. Heavy 40-oz. Syntec Delta® carpeting is used for longer wear and is standard on every MasterCraft.
We use heavy-duty ballast pumps to fill and empty the ballast tanks on our boats. They’re not only quicker than bilge-type pumps used with other systems, but they won’t lose their prime either
When a boat enters the assembly building, the hull and deck are separated to make attaching small parts, carpeting the interior and loading the engine less cumbersome. Therefore the boat moves down the line with the deck one station ahead of the hull. At the engine station, installers are careful to align the engine properly, securing it to the motor mounts and connecting the drivetrain. All holes for each powerplant are drilled with fixtures to ensure every motor is located precisely where it was engineered to be. After drilling, each hole is tapped in preparation to bolt the engine in. After the engine has been installed, the deck can be mated with the hull.
The stainless steel shaft in our rudder is sturdy and is less likely to bend under impact. We use 8 bolt struts — the beefiest in the industry — to secure the stainless steel driveshaft.
We produce our own custom upholstery using high-density foam, rotocast polyethylene frames and backs (instead of wood), premium vinyl, and heavy-duty stitching. As many as 9 grades of foam are used for maximum comfort. Every metal component on a MasterCraft is either stainless steel or other noncorrosive material. Even upholstery staples are stainless steel.
In a MasterCraft, all seat bases are part of the deck mold. The deck is mechanically fastened into the floor liner with L-brackets and mated using a tongue-and-groove process to create the most solid boat in the industry. All seat bases are made of molded fiberglass, which will not get soft in hot weather, as plastic will. Fiberglass seat bases will also retain their shape and last forever.
Rotocasting is by far the best way to build a seat. We further toughen the interior by molding nutserts into our seating structure, making it possible to bolt most upholstery to the deck. Our aluminum sundeck and rear-seat structure are solid and durable.
All MasterCraft vinyl is foam-backed for better wear and longevity. Our new pleating machine allows us to build the whole interior on the premises and ensure the quality look of true-sewn pleats. To make our interiors last even longer, we use triple-density, self-draining reticulated foam to keep your boat looking stylish for decades and to keep your seat dry.
With all systems "go," we do a final cleaning, then shrink-wrap the boats for safety before shipping them to dealers. We are the only manufacturer who shrink-wraps all boats.
The hull and deck are joined by heavy-duty screws and backed up by HDPE for maximum strength and rigidity. Our V-drive pylons are securely bolted into steel plates, laminated into the liner of the boat. Our windshields are built with thick, durable extrusion and stainless steel support brackets.
All MasterCraft towers are made locally and installed right here. We use 2-inch tubing and chromed billet aluminum to make the most enduring towers. All tower-speaker housings, tower-light assemblies, and boardracks (patent pending) are available only through MasterCraft — one source for sales and warranty.
All MasterCraft boats are run on the water for the final test before their last cleaning. Sure, it sounds like a dream job to be the lake tester, but it's no easy task. Lake testers meticulously scrutinize the boat's performance and behavior on the water, so you are spared any surprises. We hear the other guys are testing in a kiddie pool
MasterCraft is the only inboard manufacturer to custom-build and color-match trailers for each individual boat model. This ensures that every boat will sit securely on the trailer and give you, our customer, peace of mind when pulling your prized possession down the road.
It’s easy to get the big things right. The difference lies in the details. For Malibu Boats that means design based on the intricacies of ergonomics and comfort. In 2005 our attention to these details has expanded exponentially.
We have pushed our interiors a step beyond. Malibu dashes are not just a standard feature anymore, they are a showcase detail. Individually hand-wrapped and available in 12 color combinations, the 2005 dashes are a style statement. The passenger side dash in the 21.5 footers has been built up, hand-wrapped and hollowed out to house a huge 1.5 cubic foot locking storage cubby complete with a 12-volt power point and a slip-less rubber mat. We have thought of everything.
It’s hard to take in the breadth of our detailing. Exclusive 38 oz. G&T Marine vinyl shrouds tri-ply interior foam, providing multiple densities of support to comfort and eliminate sags. The sensual lines of the interior are punctuated by the precise seam alignment connecting the inviting seating areas. The premium nylon carpeting invites toe wiggling pleasure with its plush feel and tough bounce-back capability. The combination confirms Malibu is the right choice. The only choice.
The new standard flip-up bolster seat elevates the driver to a new vantage point, increases visibility and removes all doubt when obstacles come into question on the water. Safety is always foremost in our minds.
Our new billet dash insert is machined from a solid piece of aluminum, then chromed. Now standard in all Wakesetter series models, it is a shining demonstration of the level of refinement to which Malibu has ascended with the 2005 model line up. It may seem like just a small detail, but at Malibu superior craftsmanship knows no boundries
A fine exterior is only half the story of an exceptional boat. It’s only complete when what doesn’t show equals the quality of what does. In the case of Malibu Boats, what you don’t see is the patented Fiberglass Engine Chassis System (FibECS). FibECS is chemically bonded to the interior of the hull at a molecular level with Weld-On®, to achieve unibody construction. The engine is through-bolted, not tap mounted, directly to FibECS at eight separate attachment points to insure level, vibration-free engine operation and to disperse load equally over a greater area. We refuse to compromise the structural integrity of your boat. FibECS also uses active air induction to funnel clean, cool air to the engine for increased performance. It shelters the boat’s wiring looms from the extremes of a marine environment. Proven innovations like this have made Malibu Boats the number one tow boat manufacturer in the world with zero failures of more than 24,000 FibECS reinforced Malibu boats in operation today.
From multiple layers of hand laid bi-directional and tridirectional fiberglass to the industry-leading ceramic coring, Malibu boats are built to extremes using the finest materials available.
We are not willing to relinquish control over the design and construction of signature elements. Malibu’s patented swivel-head pylon, like many other key Malibu parts, is built in house by Malibu employee-owners to guarantee reliability and improve production efficiency. Tested to resist up to 2,000 pounds of pull, the swivel-head pylon extends the life of your rope by swiveling with the slalom skier at the command of a dual needle bearing core. Available in chrome or standard brushed aluminum, the swivel-head pylon is just another example of Malibu construction, a step beyond.
Our close working relationship with Medallion Instrumentation has allowed Malibu Boats to produce one of the most visible and accurate gauge clusters in the industry. Measuring 5 inches in diameter, these Malibu/Medallion gauges are servo driven for extreme accuracy and constructed to stand the test of time. Encircled with a stylish chrome bezel these eye-catching gauges supply up-to-the-second information.
Malibu Sound Suppression Technology.
Walk softly and carry a big stick. Or drive a well constructed boat. Silence denotes precision and with precision comes power. Malibu boats are classified as strong silent types thanks to the high caliber of their components. Our exclusive Malibu Sound Suppression Technology (MSST) lines the laminate of almost every Malibu model and eliminates prop thrust vibration and drive train noise. Our Space Age Composite Flooring System is engineered for longevity as well as noise restraint. Fused with the Fiberglass Engine Chassis System (FibECS) the Space Age Floor plays its part in unibody construction and adds even more rigidity to a Malibu boat. You also won’t hear a peep from mechanical fasteners working loose in a Malibu. Deck and hulls are blueprinted for an exact fit and then welded together with WeldOn® the leader in marine structural bonding.
All Malibu boats are born to perform, but the goal is not just high performance. It is on-demand, consistent, controllable yet unrestrained performance. We have no tolerance for half measures. It is this dedication to power and performance that has driven Malibu Boats to 11 world records since 1999 and put us at the top tier of the water sports industry.
Our desire for powerfully versatile water sports performance has led to industry-first innovations like the Wedge and a new, patent-pending, Adjustable Rudder. Our search for accurate on-demand information ignited the development of Malibu’s Ballast Monitoring System (BMS) to give professionals and aspiring pros the tools they need to push their abilities. Precisely machined CNC propellers and laser-straight Gorilla tracking fins join the list of Malibu’s performance-enhancing originality. All this performs at the command of Indmar Marine Engines, the power behind 10 of the past 13 “Tow Boat of the Year” awards.
The all-new Adjustable Rudder
Find control exactly the way you want it with Malibu’s new Adjustable Rudder. It is a versatile innovation for those who are serious about their slalom, but do not want to sacrifice a finger-tip controlled leisurely cruise. Exclusive to Malibu, this adjustable load rudder is standard on all models and can be adjusted with the quick turn of an Allen screw. Set it to neutral for a “no load” day of wakeboarding and running the lake. When it is time to run the course, customize the load in either direction for the perfect pull.
Ballast Monitoring System
Malibu, in partnership with Medallion Instrumentation, has developed a new Ballast Monitoring System (BMS), standard in Wakesetter VLX, Wakesetter LSV and Wakesetter 23XTi. The BMS extends the benefit of the Malibu Launch System (MLS). Ballast tanks are measured in quarter tank increments and can be monitored on the LCD display in the speedometer. With as much as 1,250 lbs of ballast to keep track of, Malibu has introduced an in-dash Ballast Monitoring System (BMS) to allow riders to fine tune the placement of weight in each area of the boat. Riders agree, this type of detailed system information is invaluable and the first of its kind in the water sports industry.
Gorilla Fins were designed for Malibu’s powerful line of V-drive boats. These monstrous 120 square-inch fi ns plunge deep into the water beneath the boat and offer an oversized surface area to allow a level of tracking and handling only matched by Direct-Drive boats. The sheer size and design of these fins steadies the boat and creates a rock solid center pivot point, thereby improving turning radius and overall maneuverability even with a rider cutting hard behind the boat.
Malibu’s exclusive hydrofoil technology, the Wedge, is more convenient to use than portable ballast for hull displacement, and safer. Creating approximately 1000-pounds of down force on-demand, the Wedge has played a pivotal part in securing Malibu four of the last five “Towboat of the Year” awards. Recognized as “Impact Design of the Year” by one wakeboarding magazine, the Wedge increases the wake without adding weight, without exceeding your boat’s weight capacity limits and without a significant decrease in handling. Naturally, the Wedge is one of the most popular Malibu boat accessories. Polished Stainless Wedge also available.