tech-3When Hallett decides to add a new boat to its line, we start from scratch, with a blank piece of paper and only a concept in our imagination. Eventually the concept is captured in a scale drawing, still months away from becoming a finished new boat.

The manual labor phase begins when the initial wooden jig to form the skeleton of the plug is slowly assembled by hand. Every step must be measured precisely. A deviation of a fraction of an inch can be disastrous when your goal is perfection. Once the basic hull shape has been formed, it’s skinned with a layer of half-inch marine plywood. Then the same arduous procedure is repeated to create the deck. Finally the hull and deck plugs are ready for contour sanding. Depending on the size and complexity of the styling, hundreds of man-hours are needed to sculpture the plug into flawless form.

tech-2When the plugs are complete, a separate mold of each must be made. To accomplish that, the plugs are covered, layer by layer, with fiberglass mat and cloth and soaked with resin. Once cured, the molds are reinforced with a steel framework and separated from the plugs. If the process has gone according to plan, the molds will now be ready with only a minimum of detail work to begin pulling production hulls and decks.

tech-5For the birth of a new Hallett, the entire procedure may take up to a year or more. But the wait is well worth it as evidenced by our many industry awards from leading national boating publications.