Here is the first day of hull layup for Shannon 53 HPS#1. You can recognize Walt Schulz. He is wearing a white Tyvek jumpsuit and respirator.

Shannon 53 HPS: Lofting and Hull Mold
Shannon 53 HPS: Constructing the Interior
Shannon 53 HPS: The Deck
Shannon 53HPS: The Launching
The ballast is then encapsulated in a resin mastic material called Multi-bond. Layers of laminate will then be added on top.
This is mid point of the layup of Shannon 53 HPS hull #1... the Corecell 1" PVC linear foam. The Corecell is unicellular; it can't absorb water like much cheaper balsa does, and it better endures constant stresses than cheaper cross-linked PVC cores that tend to shear internally when used in a hull. The Corecell is set in Corebond mastic, the pink material. In Europe, hulls made with the Shannon method of composite core hull construction are rated twice as strong as the same thickness solid laminate hulls.
(Below) The finished hull in the mold with more layers of bi-axial laminates are applied to the inner hull surface after the core. Additional layers of laminates are placed in high stress areas like the waterline, chainplates, etc.
Walt Schulz the obstetrician, as he directs the Shannon crew separating the halves of the hull mold as Shannon 53 HPS #1 is born
Tuesday, November 17, 2008
The one piece hull of the first Shannon 53HPS, flawlessly fair and without any imperfections!
Walt Schulz and the happy owner of Shannon 53 HPS hull #1, Carl Nelson, stand inside the hull.
GRIDWORK AND BULKHEADING The stringer system and solid mahogany grid work is installed in Shannon 53 HPS #1. Bulkheads are next. Notice the centerline that estabishes all the relative locations of the interior woodwork. At Shannon we still are building a wooden boat interior inside a fiberglass hull and deck, taking advantages of the positive features of state-of-the art high tech composite construction methods and tradtional boatbuilding skills.

(above and below) Here Rick Frazier is working on the hard top that will cover the aft lounge deck. This promises to be one of the most inviting areas of the Shannon 53 HPS. The owner of Shannon 53 HPS #1 commented that looking at all the nice spots to lounge and sail on the Shannon 53HPS deck has ruined his winter vacation plans as he can't find any place that will be as nice to be as onboard his new Shannon.
The tooling process for the deck for the newShannon 53 HPS continues. Walt Schulz has been making extraordinary efforts to ensure that the ergonomics for standing, sitting, and moving are correct. Tooling projects like the Shannon 53 HPS deck utilize the wooden boat building skills of the Shannon crew.
Like all Shannons, the 53 HPS uses solid lead internal ballast. Solid lead is the best material for ballast as it is very dense relative to its volume. It is expensive, so a lot of companies uses scrap iron or even concrete instead of lead for ballast. This effects sailing performance, as their boats heel a lot more in heavier winds. With internal solid ballast there are no keel bolts which can fracture during a serious grounding. When enough keel bolts fail, the ballast falls off with catastrophic results. That is why Shannon does not use external lead keels.
A heavy construction crane lifts the lead into the hull
The lead in place. Note the deep bilge sump aft of the ballast.
APRIL 2009
The final step in preparing the Shannon 53HPS deck plug to make the deck mold is to wax the plug. The plug is the positive shape. The mold will be the exact negative of the plug. Every deck that then is produced in the mold will look exactly like the plug. Even though we have invested hundreds of thousands of dollars in the plug, its only function is to make the mold, and after the mold is made, the plug will end up in the dumpster.

(below)The orange tooling sprayed onto the plug to start the mold making process. Subsequently, the multiple layers of fiberglass will be applied to construct the new deck mold.
MAY 2009
Pulling the Deck Mold

(above) The deck mold in the air, with the dark gray deck plug next to it
(below) A large crane is used to separate the Shannon 53 HPS deck mold from the deck plug, then to rotate the deck mold to an upright position.
(left) The mold being turned in air
(above) Here's the mold being separated from the plug
(above left) The mold being turned in the air (above right) Here's the mold being separated from the plug
(above) The finished mold sees daylight. The orange color is the special tooling gelcoat

(left) Walt Schulz, forman John Arraujo, and the Shannon fiberglass crew that built the Shannon 53 HPS deck plug and mold, all smiles for a job well done.

While the deck mold was being completed, the next step in the construction of Shannon 53 HPS #1 involves installation of mechanical systems (see Shannon 53 HPS Construction Part 3: The Interior)










Here is the hull of Shannon 53HPS #1 being moved from Shannon's fiberglass shop to our front building. Note the sleek lines of Walt Schulz's design and voluminous interior
(below)The hull for Shannon 53 HPS #2 is out of the mold. Hull #2 will feature all all teak interior with a three stateroom and three head interior plan.
(right) Here are the four solid lead pieces of the
53 HPS's ballast. These pieces are cast in a custom mold at a local foundry so that the pieces are snug inside the keel cavity.