Daniel's Head Boatbuilders Ltd./Novie Boatbuilders Ltd.

PHOTOS
See The Construction Process

Steps in the process of the building of a Cape Islander fishing boat:

New boat's name: "Emma's Pride"
Purchased by: E & C Nickerson Fisheries Ltd., The Hawk, Nova Scotia, Canada

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	Three workers waxing the mould in preparation for making a brand new hull. It is important to do a good job so the mould will release easily when the hull is finished.
	This picture shows a fourth worker reaching down to wax the top of the mould. He is standing on a platform attached to the outside of the mould. The mould is orange.
	Two workers cutting 'cloth'. They are cutting Mat and Stitchmat Fibreglass into all the various sizes they will need for the new hull. This way they won't have to do this during the laying up process.
	After cutting the longer pieces of Mat and Stitchmat, they are rolled up and stored on a piece of clean, pressed board, and are kept covered with plastic to protect them from overspray.
	Now, the gel coat is applied using a spray gun. This will be the color of the boat when it comes out of the mould. The camera flash reflects off floating fibreglass. Workers must wear protective masks.
	When the gel coat is dry, fibreglass pieces are are laid a section at a time. The first step is to spray the area with the resin/dryer mix where the first piece will go. Protective masks are worn due to the spray.
	Next, a piece of mat fibreglass is rolled down into position, over the sprayed area, making sure there is some overlap with the previous piece (dark pink).
	This first piece of two is then sprayed. The boat is first done all over once with 2 mat layers called the skin layer. Further layers of mat and stitchmat are applied section by section.
	Once the first piece is placed, workers must roll it smooth with metal rollers. We don't like to see any air bubbles. Smoothly rolled pieces make a stronger boat.
	A close up of the piece being rolled. The rollers are attached to long poles but can be removed for rolling within arm's reach.
	The last touches are applied. The process will repeat with the second piece and then they will immediately start the next section. Working in fibreglass is smelly, itchy, hard work.
	The two halves of the mould are finished and have now been joined together. Now the keel must be strengthened. Here, a worker lays a piece in the stern. There is only a temporary false stern as this hull has been widened.
	After each piece is laid, the sprayer sprays it to wet it with the resin/dryer mix. Behind the worker at the right you can see the bilge string piece which has already been fibreglassed firmly onto the hull.
	The workers will continue along the whole length of the keel. There are many layers in the keel to give the hull strength, and it is very hard to roll.
	Once the keel has dried it is is time for the bulkheads to be put in. Templates are used to trace out the shape of each bulkhead onto plywood.
	The bulkhead is cut to fit the section it goes into. There is a different template for each bulkhead to be put in.
	Here, you can see one bulkhead is half ready. Two sheets of plywood must be used, overlapped, to span the entire width of the boat. They are getting the second piece ready now.
	This is the first bulkhead in the bow section all ready and glassed to the hull.
	Employees work together to apply fibreglass pieces to each bulkhead to add strength and water resistance. They will do this for each of the bulkheads.
	Another view of the bulkheads. During the process, the workers have to cross bulkheads to get back and forth. Dangerous and not easy for shorter people, especially when trying not to step on wet sections on the floor.
	View of top right of mould from floor. The hull is finished and all fibreglass work has dried. It is now ready to come out of the mould.
	The new hull (left-cream) is being separated from the mould (right-orange). The mould is first unbolted and is gently pulled apart.
	The hull has been taken out of the mould shop by a local trucking company, and is ready to be backed into the finish shop. A worker spreads salt where the tires will go for traction on the snow.
	The hull is carefully backed in to the finish shop to the left of the mould shop. This is a slow process as the hull must be positioned within the wrap-around upper deck for easy access.
	View of the hull being backed into the finish shop from the other side of the truck. The driver does a quick walk around to see where 'everything is' before backing in more.
	The new hull is in the finish shop and is ready for construction to begin.
	Work has begun on the boat. Our master carpenter has begun to build up the most forward bulkhead. This will be the wall where the entrance to the living quarters (cud) is.
	Work progresses quickly. The floor is started. The camera flash reflects off floating dust or fibreglass in the air.
	Fibreglassing.
	Cutting lumber to size.
	View of floor from stern.
	Work has begun on the house.
	Carpenters have begun framing top of cud area.
	View of side from exterior of boat.
	Another view of work being done on the house from stern.
	Shot inside the house of work done to this point.
	More work has been done on the house and is starting to look more like the finished product.
	Port side view of outside of hull.
	View of workers on the 'upper deck'.
	View of rudder area.
	Nice view of painted house from the stern.
	View cupboard area coming along fine.
	View of table/bunk area in the cud.
	Photo of steering house inside with even more finished.
	Shot of steering house through the door.
	View of starboard side showing ribbands.
	Nice shot of the house taken from outside of the boat on the starboard side.
	Shot similar to above taken from just a little further back.
	Another view of sink/cupboard area.
	More has been finished in the cupboard areas.
	View of the bunks after being varnished.
	View of dining area.
	Inside view of steering house taken from the wheel side.
	Boat is finished! Proud owner and crew stand in front of their new Cape Islander while she still sits in shop.
	"Emma's Pride" comes out of the finish shop.
	Being launched at the wharf in West Head, Nova Scotia.
	View of boat being carefully backed into the water.
	"Emma's Pride" officially launched, 2003.
	"Emma's Pride" positioning itself alongside "Jessa & Austin", another Daniel's Head hull finished by Greg Symonds
	More manuevering.
	Side by side.

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