Ferry Boats

  • 360 Discovery 1

    360 Discovery 1

  • 360 Discovey 1 in travel lift

    360 Discovey 1 in travel lift

  • Engine Repair

    Engine Repair

  • Topside Repair

    Topside Repair

  • Repairs under portable shed

    Repairs under portable shed

  • 360 Discovery 1 after refit

    360 Discovery 1 after refit


* Purpose built multihull travel lift for wide beamed ferries up to 80 tones and 8.5 meters beam

*Construction and repair using all boatbuilding materials

*Engineering and Metal fabrication

*Engine, Transmission, Genset and Hydraulic servicing and installation

*All Internal Construction and Finishing




* Design and Build of the Kawau Kat fleet now the Discovery Fleet
* Design and Build of the Cruise Cat for Lake Taupo
* Extensions on Discovery 1 & 2
* Hull repairs on the Discovery fleet
* Servicing of the Discovery fleet
* Re-Powering of Discovery 2
* Full external refit and repaint of Discovery 2 & 3
* Servicing of Fullers Tiger Cat
* Service, maintain and repair Osprey

And many more…


Illustrative case history for a Ferry Boat

A routine survey surfaced structural damage requiring a major repair job. An early repair date was scheduled for a rapid turnaround which was achieved even though, upon inspection, the damage was much worse than expected. As well, to minimize total annual out-of-service time, routine and preventative maintenance were handled at the same time as the major repair, extending the time before the next haul out.

This ferry does a run around the Auckland Harbour. The routine survey surfaced that the structural integrity of the hull behind the starboard belting had been compromised through an incident involving a major impact to the belting. This meant that the belting didn’t have the level of support required on the starboard hull. The ferry came to the yard and was hauled out, washed down and placed under one of our portable sheds on the hardstand so the repair could commence.

After a quick investigation it was found that the foam core in the hull behind the belting was severly crushed and damaged providing little support which was the reason for the problem. The belting was removed and taken away to be tidied up as it would be reinstalled after the repair was completed.

The repair needed about half the hull opened up, so the outside skin of the hull was cut away and the core material was removed along the required section. Once that was complete the team got to work reconstituting the topside back as a solid structural laminate from inside skin to outside skin to make the hull stronger and directly transfer forces exerted on the belting through to the internal structural frames of the boat.

The lay-up consisted of a number of layers of chopstrand matt, woven roving, and double bias fibreglass cloth with vinyalester resin. Once the glass had cured it was then bogged out with microballons and faired up using big pizza sanders.

Once this was complete the painters got involved applying epoxy primers and undercoats building up a good base and locking it all in. The undercoat was knocked back and the topcoat applied and blended in with the original paintwork so the repair wasn’t so visible.

Next the refurbished belting was brought back and reinstalled, bedded onto the hull with terostat sealant and bolted in place. New stainless steel clashing was screwed onto the outside face of the belting and the job was complete.

While all this was going on there was another team of specialists making repairs to the other beltings, scarfing in new bits of timber where required and replacing stainless clashing. As well, engineers were busy servicing the engines, genset, fabricating the stainless clashings for the beltings, and all the running gear to avoid the ferry being hauled out at a later date.

All these jobs were completed in one week, the ferry was launched, the systems were run up and checked, and it was back in service in rapid turnaround.