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Latest Production News From Clark (Philippines)

By Ian Farrier

Updated April 8, 2016

I have just returned from a week in the Clark Freeport Zone factories, where we are starting to see more
progress. Three F-boats are currently being put into production at Clark these being, the F-22, F-33, and
the F-45. It has taken some time to source the necessary quality materials but this is mostly done, and
mold making can now finally proceed:

One of the F-22 float plug halves being prepared for making production molds.

Tooling gelcoat now going on. This is being applied by a new addition at Multihulls Direct, Kiwi boat
builder Jeremy Thomas, who comes from 15 years of building some of the fastest yachts around the
world, this including TP52s, Volvo 70 and Open 60s plus the Flying SL33s Team NZ used for testing
in the last Americas cup. Another container of F-22 plugs and molds should be leaving from New
Zealand this month and this will be enough to start building F-22s.

Meanwhile the F-45 and F-45R currently under construction are proceeding well, and will soon be
structurally complete with interiors formed:

Kim Alfred's carbon F-45RC "Cheekee Monkee" with exterior being laminated. This will
have a Southern Spars carbon wing mast, and is shaping up to be quite a spectacular craft

The wide and safe side decks of the all glass F-45.

The F-45RC profile

Side view where the size is very apparent

...and it is just as big on the other side!

Meanwhile, in the second factory next door, the 2017 model F-33 is being developed as a fully molded
production boat, photo above showing the deck mold being made. F-33 float mold is in foreground.

Deck core now in place and this mold should be finished this week. The hull mold will then follow.
Note that only one hand crafted all epoxy F-33 remains available for delivery this year, and then there
will be no more of what will be a rare and very unique extra light epoxy model. The fully gelcoated
production version will be a little heavier, as are all such boats. However, the new production F-33
will be lighter than others, due to its advanced construction/design with no heavy interior liners being
used. However, custom interior variations will no longer be possible, as everything has to be locked
in with molded production boats, such variations being too expensive and disuptive to do.

The F-33 beam molds are also now in Clark, and Farrier Marine team member John McCormack was
there last month to show how they are made. With molded production now not far away, the F-33X
form frames that can be seen in the background (for epoxy version) are being taken down.

This photo shows the beam bottom being infused - a first for Clark

Beam top now infused. It will not be long before we are also infusing decks and hulls for both
the 2016 F-22 and then the 2017 F-33.

Meanwhile, back at the New Zealand factory:

F-22 hull #10 as taken out of the mold in March

Production F-22 Developments

All going well, the Clark built F-22 should be available this year, and this may be called the F-22S.
It will initially be the basic standard rig model only, to ensure it can reach the necessary high
production rate very quickly. New lower pricing for this model will be available on the Online
store soon, and all current depositors will have first option for this boat. This means that the
holder of say No. 19 slot could then become #1 out of the Philippine factory, if no one ahead
decides to transfer over, and so on.

The last major item, the F-22 main hull master plug is now made, and this will be shipped to Clark
later this month. This was the largest single resin infusion that we have done with 92kg (202lb) of
resin being infused in one shot. Making this plug has held up NZ production for a little while, but
it was necessary to do in order to increase the production rate overall.

Master plugs are used to make additional molds, and are essential for establishing any high volume
production boat. A production rate of one a week requires at least one mold, while a rate of two per
week would require two molds from the plug, and so on with 5 molds required for five per week. So
a significant investment of time and money is needed before full production volume can be reached.

Thus it is still early days, much work remains to be done, with a lot to be worked out, but it looks like
the wait time will finally start to come down this year. To get in line, $500 deposits are still being
accepted, and the next available hull number is 97.