Miliner Marine Services
Boat repairs, refinishing and maintenance by Miliner Marine Services, Eliot, Maine, USA Boat Building & Repair
Eliot, Maine, USA


David V. Miliner - Shipwright
207-439-4230

Serving the North East USA since 1977


Custom "One-off" Fabrication


Sometimes the need arises to modify the existing structure of an area of a boat, or to fabricate a finished fiberglass component without the availability of an existing mold- often referred to as "one-off" parts. Both can be achieved through many methods. We have on occasion created a finished part by building a "plug" in the shape of the desired part and pulling a single use "splash mold" from the plug to allow us to laminate a solid part with a gelcoat surface just as the hull and, deck, and component parts of the boat are manufactured at the factory. This usually results in a part that needs little cosmetic refinishing. At times- for components with a relatively simple shape- we have skipped the building of the plug and simply fashioned a mold with a Formica molding surface from which to pull the part. We employed this method back in 2008 to replace the delaminated swim platform ( 2.5' x 13.5') on a 53' Jefferson powerboat. This results in a solid part as well but usually requires additional cosmetic refinishing to make the part usable. Another method for fabricating "one-off" components is by the use of fiberglass panels to create the desired component. Pre-laminated panels- cored or solid glass- can be purchased or fabricated on a "splash mold" made from a sheet of Formica glued to a sheet of plywood. This allows for the modification of an existing part or the creation of more complex parts, but usually requires the entire viewable surface to be refinished with gelcoat or paint.

Sample Project 1: In 2002 we modified the fiberglass flybridge component for a Duffy 35 that the owner had purchased as a kit early in the 1990's. Over the course of a ten year period he, and a random marine contractor or two, had done a beautiful job of assembling the parts and finishing the interior. The boat was too high to travel down the road with the flybridge in place so we had to fabricate a series of flanges that we fashioned out of fiberglass panels created on a flat "splash mold" and then fiberglassed to the cabin roof to allow for the removal of the bridge for transport. To allow for the installation of two helmsman chairs on the bridge, without disturbing the appearance of the overhead inside the cabin, we had bolts tack welded to a metal plate which we then set in place with an epoxy putty, capped with a pre-laminated fiberglass panel, and glassed to the bridge deck. These steps and the modification of the flybridge component can be seen in the pictures below.
Boat repairs, refinishing and maintenance by Miliner Marine Services, Eliot, Maine, USA Boat repairs, refinishing and maintenance by Miliner Marine Services, Eliot, Maine, USA Boat repairs, refinishing and maintenance by Miliner Marine Services, Eliot, Maine, USA
Duffy 35 - We used a pre-laminated Baltek balsa cored panel to close of the aft face under the dash area of the flybridge component. Duffy 35 - This shows the modifications that the owner requested. Two access opening were cut into the aft face with an inner framework to mount door assemblies. And the area where the helm. throttle, and instrument panel were to be mounted was rebuilt at an angle. The inside of the bridge was then finished off using Awlgrip topcoat. Duffy 35 - This shows the flange assembly that was glassed to the bridge deck for the flybridge to be bolted to and the metal plate and fiberglass panel assembly that would also be glassed to the deck to support the helmsman chairs.
Sample Project 2: In 2012 the J 24 racing sailboat that we had restored the year before came back to our shop so we could assist the owner with installing all the boat's hardware. He also had us create two areas of positive buoyancy with the intention of making the boat unsinkable. We replaced the old deteriorated v-berth with one constructed using 12mm marine Meranti plywood which was then glassed to the hull to create a watertight area under the berth. The entire cockpit locker area was made watertight as well by sealing the bulkhead forward of the cockpit and sealing the cockpit seats shut.
Boat repairs, refinishing and maintenance by Miliner Marine Services, Eliot, Maine, USA Boat repairs, refinishing and maintenance by Miliner Marine Services, Eliot, Maine, USA Boat repairs, refinishing and maintenance by Miliner Marine Services, Eliot, Maine, USA
J 24 - The soon to be watertight v-berth under construction. J 24 - The Meranti marine plywood in place- all seams would be sealed with fiberglass cloth and polyester resin. J 24 - The cockpit seats- the seat drains have been closed off with pieces of fiberglass panel, and the seats bedded and screwed into place.


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Copyright © 2013/2018 Miliner Marine Services, Eliot, Maine, USA, dmiliner@msn.com
Installed February 6, 2013, Last Revised February 15, 2018 - Hosted and maintained by Don Robertson