Design For Series Production
components for hulls and decks. The interiors were built piece by piece inside the hull, not unlike custom methods that
have been employed for years.
Today, most manufacturers cut component pieces in quantity from accurate templates, sub assemble the parts into vari-
ous interior components such as galley units, lockers, berths, heads, and then bring these sub-assemblies together on a
master jig. The interior is basically completed on this master jig and then lifted as a unit into its hull on the assembly line
where it is attached to the hull usually by bonding bulkheads, partitions, etc., with FRP lay-ups.
The master jig properly designed will locate accurately each interior component insuring proper fit of the final assembly to
the hull and deck. Many builders utilize FRP pans on which the wood components making up the interior are assembled.
The FRP pan becomes the locating jig and cabin sole. (Figure 5)
Electrical System - In the past, using schematic wiring diagrams as a guide, electricians armed with coils of multi-colored
wiring went aboard the partially completed boat and strung their wiring. A laborious task at best considering the many
obstacles in the form of interior joinery the electrician had to cope with.
The more advanced systems of today utilize a wiring harness that is pre-assembled on a board on which the various wiring
circuits are laid out full size. These pre-assembled harnesses are then installed on the interior unit while it is under con-
struction on the master jig. Installing the wiring at this stage permits working on the unit from the outside as opposed to
running it inside the boat which has reduced the labor hours considerably and improved the overall quality of the work-
manship. It is important, however, to consider access to connectors once the interior unit is placed inside the hull. This is
sometimes overlooked in the interest of efficiency at the plant level. The service yard or owner is
appreciative of this
approach. Testing of the electrical system is also possible during the sub assembly stage and faults easily found and cor-
Dec. 2014 Page 9