The Hunt 80 starts coming to life with the first step in the hull construction process, spraying on the gelcoat, well underway in this photo. Thickness is maintained within very close tolerances by an experienced technician. The gelcoat becomes the visible exterior of the hull once it is pulled from the mold. After the gelcoat has been applied and cured, the lamination process will be begin. The scaffolding used by the laminators is also seen in place and ready to go.

The Hunt 80 mold was designed to accommodate various hull lengths, and also different propulsion systems including inboard shafts, pods and waterjets, to suit the owner’s performance requirements. In this case waterjets, with which Hunt has extensive experience in both commercial and pleasure applications, were selected. The mold was extended some five feet to optimize performance and accommodate the extra weight and space requirements of this uniquely capable propulsion system. 

The hull lamination is progressing. First, numerous layers of fiberglass are laminated against the gelcoat, followed by a structural foam coring being bonded to the inner skin using vacuum bagging for high integrity between the materials. The next step will be laminating the outer fiberglass skin to the core, effectively creating a continuous I-beam structure from sheer to sheer. Coring provides a stiff structure at moderate weight, along with high strength and impact resistance.  Hull portlight (window) inserts can be seen just below the sheer.