From the engineering to the integration of advanced proprietary materials, every aspect of the design and manufacturing process at Island Packet Yachts is built to endure.
Design and Engineering
Every Island Packet begins here, in the mind and on the drawing board of Naval Architect Bob Johnson. Bob and the IP Design Department continue to bring together the traditional virtues of superior seakeeping and classic good looks with the performance attributes of the modern Full Foil Keel® and contemporary underbodies.
PolyClad® Gel Coat System
Island Packet’s proprietary gel coat formulation, PolyClad®, is part of a two-part system for protection against osmotic blisters. PolyClad® gel coat, combined with a layer of fiberglass and vinylester resin (used in the skin coat of the hull) provides superior protection against osmotic blistering. Island Packet Yachts became the first US sailboat builder in 1988 to offer a 10 year warranty against osmotic blistering and remains one of the few in the industry to offer this level of coverage.
After the gel coat has had sufficient time to harden, large sheets of fiberglass are placed into the mold for high strength and impact resistance. Using a unique pressure fed roller application system developed exclusively for Island Packet, resin and catalyst are applied in carefully controlled quantities onto the triaxial fiberglass sheets. Another important part of Island Packet’s lamination process is the application of Polycore® - an inorganic, glass microsphere and resin mixture that is used as coring material.
Island Packets gain significant strength from the structural floor grid. The grid is molded with knitted fiberglass and resin and further reinforced with Polycore® and multiplemarine plywood stringers. This unit is designed and constructed to be an integral component of the hull when bonding is complete. In addition to adding structural integrity, the structural floor grid is the foundation on which the interior is constructed.
Following the installation of tankage and the Yanmar® diesel engine, trim carpenters carefully fit and securely fasten in place bulkheads, cabinetry, countertops, and the like. Although the wood components are made weeks before in the mill, precise fitting and joinery work is essential during this important stage of construction.
Island Packet’s electrical systems, repeatedly singled out in Boat of the Year award reviews for their meticulous installations, become part of the yacht at this stage. These include the addition of numbered, color-coded, pre-tinned wiring, AC and DC electrical panels, lighting systems, batteries, battery chargers, and electrical outlets.
When the deck has been fitted to the bulkheads, the integral hull flange is prepared for the fastening of the deck. First, holes are drilled every six inches through the deck and hull flange. It is then fitted with a watertight rubber gasket material and then coated with copious quantities of 3M® 5200 urethane sealant. The deck is then lowered, 1/4” diameter s/s bolts are fastened from underneath to permanently attach the deck to the hull. After the teak toe rails are fastened, stanchions, cleats, rails, and genoa tracks are all mounted to the toerail and thru-bolted to aluminum backing plates.
Over a period of weeks every inch of each Island Packet is thoroughly inspected; finishes are added to wood surfaces, the smallest particles of construction debris are removed, and excess sealant is cleaned away with the most delicate tools and discriminating eyes. Each and every Island Packet ships “Show Ready”.
Ready for Transport
After months of labor, the yacht is now ready for delivery to dealerships throughout the United States and to ships for transport to the United Kingdom and Europe.