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The OC Tender workshop in New Zealand manufactures lightweight, carbon-fiber dinghies using a foam-sandwich construction method. The process begins with CNC-milled molds for both the hull and deck.2:33 Technicians apply a gel coat to the mold before hand-laminating layers of fiberglass or carbon fiber, depending on the specific order.3:09 A 10-millimeter PVC foam core provides structural rigidity while maintaining a low overall weight.3:00 For high-stress areas like the transom and outboard mounting points, builders incorporate unidirectional carbon fiber reinforcements.3:09 The assembly involves vacuum-bagging the laminate and foam to ensure a strong bond.5:05 The final hull receives an epoxy undercoat and a polyurethane gloss finish to protect against beach abrasion.9:20 The design features a sharp hull edge for efficient planing and a protective rub rail to prevent damage to the mothership.9:04 The workshop also produces carbon-fiber oars and centerboards using resin-infusion techniques.17:05 The build process emphasizes field-repairability, allowing owners to perform maintenance using standard materials found on board.12:46

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