Last week I had the opportunity to take a Malibu factory tour at the Merced, California location. I was very impressed with the amount of organization and attention to detail that goes into the manufacturing process start to finish. I was lucky to have a great tour guide. Anyone who is able should take a tour. Seeing some of the new things for 09 were great and learning exactly what is involved in making a great boat was very informative. They say pictures are worth a thousand words so here it goes.
Molds after gel coat
2 paint booths that are each able to hold 2 molds.
Gel coat sealer. All sealer sprayed is now blue for better color tone of gel coat.
Sealed mold ready for fiberglass.
First layer (outer layer) of fiberglass is applied with a chopper gun and rolled down by hand. The chopped fibers are used in the first step to insure there are not any air pockets and that deep corners and sharp edges get correct about of coverage.
Mold for 2009 VLX. Fiberglass mating of various weight is applied to specific areas for optimum strength. All fiberglass work is done in a temperature controlled area to keep cure time consistant all year long. During extreme heat crews start at 5am.
Areas where items such as lifting eyes, wedge, grab rails or cleats are mounted receive additional reinforcement and more fiberglass from back side of hull or deck.
Floor board is precut and then fiberglassed into the hull. The material used is manufactured to minimize vibration and control noise. The multiple holes that are cut toward the outer edge of the floor are used to inject floatation foam so a Malibu will bob in the water instead of sinking in bad situations. I hope no one ever needs this but its nice to know it is there.
The all fiberglass stringers are bonded to the hull and act as the backbone for the boat. The stringers are hollow and will direct air to the engine compartment from the vents on the front of the boats bow.
09 VLX in first day of assembly.
09 VLX air intake vent location that will be connected to the stringers via hoses to feed air to the motor.
Detail of 09 VLX hull
Great looking windshield.
09 VLX after top deck and carpet are installed
Passenger side dash board after hand applied and shaped foam padding and before vinyl
MaliVue dashes ready for a new home.
Wrapped and ready dash board. New push button start taken from the 08 Corvette boat. Bezels are not installed around switch panels yet.
Direct drive in production.
Material rack for computer controlled cutter. Type in the model boat and let the pizza cutter type machine do the rest.
Direct drive assembly area
Aluminum honey comb sheets used for rear sun deck and one of the floor panels. Used for high strength to weight ratio. This will make opening the rear hatch easier without sacrificing rigidity.
One of the upholstery fabrication areas. Machine behind table saw is a CNC machine for cutting out the ABS bases for seat cushions.
Material cutouts from the machine are brought here to be sewn into covers
Production line for the seat covers, foam and ABS bases. Each person is assigned specific parts to ensure consistent top notch quality in every part. During break time poker skills are practiced.
A rack of Indmar motors. Malibu California receives roughly one shipment every month. Malibu California will average 150-175 boats in full production every month.
Chevy LS2 for Corvette ZO6 Malibu. Malibu California is the only Malibu plant that produces the Corvette boat. There are also Malibu plants in Tennessee and Australia.
Dash bezel for MaliVue dash fresh out of one of the many CNC machines in Malibus own metal fabrication department.
VTX waiting for a lake test in the morning.
A look back at the new graphic that matches the new VLX hull.
A VTX that just finished a 20 minute lake test of all features including ballast and wedge. Every boat recieves a 20 minute lake test and a 150 point inspection before going to final assembly and detail. I want this job!
Another VTX next in line for a lake test and inspection.
MaliVue in VTX with standard key ignition.
Butt shot of new VLX. New grab rail fits the quality and high standards of Malibu.
23 LSVs in line to be lake tested the next day.
Shot of the new grab rail inside the bow of the 09 VLX. With the intake grills and grab bars relocated the front of the bow looks much cleaner. New speaker grills for all 2009s.
Vent installed to 09 VLX.
Another VLX going down the line.
New for 2009, the 23 Vride. Based off the same hull as the 07 23 LSV but with the same features you are used to in the ride series. 3 piece rear sun deck, standard rocker switch dash, original Illusion X tower, wrap around windshield...
Mailbu will now be offering custom hull wraps from the factory. This can be a business name or pattern of your choice or…...
09 21 Vride. Based off the 08 VLX.
A look at the Vdrive production area.
Interior of 23LSV with MaliVue and Keyed Ignition
Optional Corvette blue metallic on a Sunscape 23. The picture does not show how great this color looks.
09 VLX interior.
These pictures and descriptions cover only a portion of what there is to experience. Hope this gives some good information to the people who don't have the luxury of being a couple hours away from the factory.
Linear Mode
