Construction Method
The Prowler NZ 10.4 is a production boat constructed from fibreglass in female moulds. This method of construction produces consistent light weight, durable, high quality components in an economical manner. However, this method does require significant tooling.

Firstly a plug is constructed. The plugs function is to provide the shape only, and is discarded when it has served its purpose. It can therefore be built from easily worked, low cost material such as MDF, and foam.

No structural integrity is required other than being stable enough to retain its shape. Upon completion the plug is surfaced with duratec, a grey paint like material which can be sanded and polished to a hard, high gloss finish.

Following a strict regime of waxing, tooling gelcoat and fibreglass are applied to the plug to form the mould. After curing the mould has a wooden or steel stiffening structure fitted prior to being released from the plug.

The mould is a precise mirror image of the plug and will produce products identical in shape to the plug.

The Prowler NZ 10.4 comprises some 40 mouldings for both interior and exterior components. Some such as the deck are large pieces and others like hatch lids and locker liners are quite small. The interior parts are fitted out with wiring, plumbing and fittings prior to being fitted in the boat, and when installed fit together like a large 3 dimensional jigsaw puzzle.

Materials
The Prowler NZ 10.4 is built utilising knitted fibreglass fabrics with a strong accent on fibre orientation. A small amount of carbon fibre is used in areas where stiffness and light weight are required.

Isophalic polyester resin is used throughout with the exception of the outside skin of the hull and wingdeck structure which is laid up with vinylester. Osmosis used to be the bug bear of polyester boats but the advent of vinylesters has made it possible to eliminate this problem.

Most manufacturers provide a vinylester osmotic barrier below the waterline only, but the Prowler NZ 10.4 has the entire outside skin of the hull/wingdeck structure in this material. Most of the structure is of composite type utilising a cross linked PVC foam core.

Fibreglass fibres are very resistant to compression and stretch and when two layers of fibreglass are sandwiched with a foam core the product is light and stiff and has excellent insulation properties, ideal for boat building.

Factory & Construction History
The Prowler NZ 10.4 is built in our facility in Whangarei New Zealand.

Ironically we have built catamarans in this building before under the Catamaran Enterprises banner, in fact we built the building in the early 1980's for the construction of the N11 sailing catamaran. In the late 80's we moved into the powercat field constructing hull moulds for 3 different sized Malcolm Tennant designed displacement hull powercats.

A major order for a run of ferries utilising these hulls caused us to outgrow the premises and we moved on, selling the building to the local council. These vessels were built as "one off's" and in the early 90's we moved into the production building field with the reproduction classic launch the Logan 33. Some 40 of these elegant narrow hulled displacement craft were produced before the inescapable logic of the displacement powercat ascended again and the Prowler 9000 moulds were purchased from Australia (see design evolution).

The facility is ideal with its fireproofed laminating room and separate assembly shop. Plus of course the waterside location makes launching a breeze.

Quality Control
Being in control of all aspects from concept and selection of equipment and materials to final pre delivery inspection enables us to keep a very tight reign on quality.

Our small team of craftsmen, some of whom have worked for us for many years, are dedicated to producing the highest possible quality boats and the pride they take in their work is reflected in the standard of the finished craft.

Reviews
Boating New Zealand PDF 1.1mb
John Goodsall "Tropicbird