The Build - E03 - Building The All-New Phenom 43

Welcome back to Phenom Yachts' "The Build," our periodic update series where we take you inside our factory to show you the steps necessary to create our semi-custom performance yachts. In today's episode, we delve into the mill room to explore the production of the new Phenom 43.

Inside the mill room, Phenom Yachts utilizes a giant 5-axis router, a unique feature that allows the team to handle intricate details in-house. Currently, the router is working on the plug for the deck of the new Phenom 43. The plug is a composite replica of an actual fiberglass part, used to create a mold. The router focuses on fine details, such as the corners and drainage channels, ensuring precision in every cut. Once the router completes its job, the mold maintenance team takes over to finalize and perfect the mold.

Moving on from the finely tuned sections, we look at parts that haven't been touched by the mill yet. Inside the console, there is uncut putty and grounded surfaces. Indexing markers are present to guide how much material needs to be removed to reach the final surface. This process ensures accuracy before the finalizing stage.

Next, we explore the plug of the deck ring for the new Phenom 43. The team creates splashes, which are thin layers of fiberglass pulled off a part to ensure precise cuts. These splashes are crucial for maintaining the exact placement of every hole, contributing to the boat's overall precision.

In the mold maintenance area, the deck ring mold for the Phenom 43 is undergoing a process called Class A, which involves sanding, buffing, and waxing. This process ensures that the fiberglass part pulls smoothly from the mold, creating a perfect surface.

We then take a look at one of the most exciting parts of the boat: the hull of the Phenom 43. The hull has undergone several steps, including applying a gel coat layer, a skin coat layer, and puttying the strakes. A peel coat layer, a layer of gel sprayed into the mold and then peeled out once cured, removes any excess wax or dust, preparing the mold for production.

After the peel coat is removed, the team starts building the outside of the boat with the gel coat layer. Once dried, the second coat, called the skin coat, is applied. This layer consists of chopped fiberglass mixed with resin, which is rolled out to remove air bubbles, preventing air voids in the final part. The skin coat also prevents printing, where woven fiberglass strands can be seen through the gel coat.

Between the first and second skin coats, putty is applied to the strakes to create an I-beam effect, adding strength and rigidity to the hull bottom. This reduces flex and enhances the boat's structural integrity. Once the putty dries, it is covered with fiberglass, creating a smooth system for the vacuum infusion process.

This episode provides an in-depth look at the early production stages of the new Phenom 43 hull. From milling fine details to applying layers of protective coats, each step ensures the creation of a high-quality, durable yacht. Thank you for joining us on this episode of "The Build." Make sure to like and subscribe for more updates, and we'll catch you on the next one.