DKG Surf Boat Construction Engineering

The DKG surf boat has evolved over the years to become a world class marine product that stands alone as the best engineered Surf Boat on the market today.

The DKG Surf Boat is the only Surf Boat using Vinyl Ester Resin infusion technology Developed by Drew and the team at DKG.

The DKG Surf Boat Process

Gelcoat- We start by carefully preparing each mould with release agents ready for the application of High quality gelcoats. We will mask up the moulds for any colour design that the customer may want then apply the gelcoats in a thin film to reduce excess weight in the boat. After the gelcoat has cured we return the next day ready for the loading process.

Fibre loading - The fibreglass fabrics are then loaded directly onto the back of the gelcoat methodically following a strict loading process. We then apply the Divinycell Foam core which has been CNC Router cut to ensure consistency and accuracy of the loading process. Once the foam has been loaded we load more multidirectional fabrics and structural stiffening to the boat again following strict process controls.

Vacuum Bagging - Once all of the fibre and foam loading has taken place more consumables are placed into the boat mould then a special vacuum bag is carefully placed onto the loaded boat. After more measured process controls and checks are carried out we will then start our infusion of the moulds.

The infusion - As the name suggests we infuse the mould with a high grade vinyl ester resin. Resin is mixed and then shot into the moulds under the vacuum bag. The resin passes through the fibreglass fabric to the gelcoat surface giving us a superior quality fibreglass boat. Once the resin has cured the boat can then be prepared for joining.

Joining - Joining the 2 boat moulds sound easy but again we use a process that involves marrying the 2 mould halves checking that the moulds not only fit well together but the measured process of the gunwales strength is not compromised in any way.
High quality vinyl ester bonding compound especially made for joining hulls and decks of fibreglass composite boats is used in every DKG Surf Boat.

De- Moulding - After the boat has been left over night to cure we will release the boat from the moulds. Once the boat has been released we will weigh the boat for the first time. The weight is always 162 kg we know this from our loading the amount of resin and glue we put into each boat. From this point the boat will go to our trimming room and be prepared for the installation of the small parts.

Finishing - After the de-moulding and trimming of the boat, the small parts will be fitted, epoxy glued and bolted into place. The finishing of the boat comes after all the small parts have cured in place and the finishing touches are carried out. We check list all of the customer’s requirements and ensure that the Boat is on Weight for Australian Surf Life Saving specifications.

DKG Surf Boats are built like no other!
We engineer our boats for repeatability and exceptional stiffness!

On weight every time!
DKG Surf Boats when performance matters!

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