This is a section of the Dehler 39's hull, taken from the location of the saildrive unit. The hefty piece is indicative of the solid laminate in the central "spine" extending through the bilges, in all load-bearing areas. Thru-hull penetrations are performed through a similar solid laminate. Note the quality of the layup of each layer of the laminate; all are even, with no indication of voids, bubbles or dry areas.

Dehlers are built using the tried and true hand layup method which, when performed skillfully, is the only lamination method that produces a uniform, properly wetted-out laminate that is all but free of voids and dry spots. Reliably, time after time. This is an element in the art of boatbuilding that has not been caught by technology.

Unidirectional, biaxial and triaxial knit fabrics are the best available, each section of the layup schedule computer cut and numbered for a precision fit. When used, Kevlar reinforcements are interwoven into the fabrics, avoiding the delamination that plagues other applications of this impact-resistant material. Resins are top-quality vinylester or hydrolysis-proof polyester or vinylester. The meat in the structural sandwich is either end-grain balsa or Corecell closed-cell foam, depending upon model and application.

The first step in the production of a hull or deck is preparation of the mold, which is thoroughly cleaned and waxed before layup begins.

Gelcoat of any color is then sprayed, beginning with the contrasting stripes, followed by the hull's main color. Once the gelcoat has cured, the lamination begins with a layer of soft fiberglass mat, both as a barrier and for a smooth external finish. This is followed by the tightly-calculated structural laminate.

At left, a Dehler 39SQ with the outer laminate nearly complete, with different elements and thicknesses readily seen.

The end-grain balsa is then applied, first to the starboard half of the hull (note the area of the 39's central spine). Once cured, the mold is turned, the port side completed, and the internal laminate added. The internal laminate is completely sealed in a durable topcoat for protection and a clean finish in the recesses of the interior.

The fully cured hull, still in the mold, is moved to a workstation to await the interior structure and decking.

Meanwhile, the deck is being layed-up with the same painstaking attention to detail. Aluminum backing plates are laminated into the deck in the areas of any hardware attachment. There is no coring material in these areas, only a rugged and troublefree attachment point.

The deck is mated to a molded inner liner (not shown) that provides a fully finished and easily maintained interior, and carries conduits for overhead lighting and wiring. Access panels are provided as necessary.