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Dufour Yachts :: How the Boats Are Built (Part 1)

January 27, 2015 10:56 am

All Dufour Yachts are built in La Rochelle, France. They all combine fine hand craftsmanship with innovative high-tech construction techniques. It all starts with the hull, and this is how it’s done.

It actually all starts in a hull mold (pictured above). It starts with a flawless, highly polished 2-piece mold and then spray layers of gelcoat that form the outer layer of each hull. Each hull is then laid up with a precise, highly-engineered number of layers of fiberglass, resin, and various core materials that are all placed in each mold by hand.

Here you can see the hull is beginning to take shape. Notice the layers of fiberglass and resin that have already been applied. Also notice how the rudder area is reinforced. All molds are built on special rollers (pictured below) so they can be rotated in-place. This makes it much easier for workers to lay the various layers.

This shot shows the underside of one of the molds. And as you can see, they are extremely well-built to extremely high tolerances so every hull comes out perfect. You can also see how much they can be rotated in place. Rotating molds speed production and increase quality because they are much easier to work on than static molds.

All Dufour hulls below 50-feet are built of solid fiberglass while the 500 GL (pictured above) and the 560 GL are laid up with solid fiberglass below the waterline and PVC core above the waterline to provide strength and stiffness. This photo also shows how workers reinforce high-load areas such as chainplate connections and keel areas with increased layers of fiberglass and resin.

Another important element of hull lamination is the fact that Dufour uses 2-part molds as you can see in the photos above. This makes it easy to release the finished hull from the mold, and it also allows for an inward-facing flange that forms a strong and elegant inward-facing hull-to-deck joint.

One of the first elements that’s added to freshly laid-up hull is the structural grid. This shot also shows what the inward-facing flange looks like and some of the other early tasks that are done at this stage like cutting out the hull ports and installing a strip of PVC core material to the aft area of the hull to provide increased stiffness.

As a result of the high attention to detail paid in the early stages of construction, each hull comes out of the mold looking clean, sexy, and fast.

Dufour is never satisfied with the status quo and their high-tech facility allows Dufour to build the best because every element of the production line is constantly being upgraded. Dufour is always to looking to improve efficiency and performance.

For more information about Dufour Yachts, contact Denison Yacht Sales, the exclusive dealer for Dufour at [email protected] | +1 954.763.3971

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Dufour Yachts – About the Brand

In 1957 a mechanical engineer named Michel Dufour, became convinced that composite technologies and materials would transform the marine industry.

He envisioned that extraordinary adventures would be achievable by ordinary people and founded Dufour Yachts in La Rochelle, France, where it stands today as one of the worlds largest sailboat builders.

In 1964 he built his first boat, by 1971 production had evolved to 300 units a year out of the facility just outside of La Rochelle. Dufour Yachts had been established.

The 70’s & 80’s saw continued growth and during the 1990’s the “Classic Range” was born which revolutionised the industry in terms of comfort and design.

Todays Grand Large & Exclusive range embrace all the history and passion of Dufour Yachts and demonstrate their tireless efforts to lead the way in yacht production and design.

Design Signature and Dufour Yacht’s DNA

A yacht must meet many functions, they have to be safe with logical interaction of all controls. They should be beautiful whilst practical and easy to handle.  Finally they must have a strong sailing performance with a comfortable and well equipped interior. 

Dufour Yachts have evolved over the years but they have kept their strong aesthetics with stretched lines, simple, clean shapes that make them immediately recognisable.

• Elegant and modern aesthetics
• Space, security and good circulation around the deck
• Easy handling with full control 
• Smart unique and functional features
• Contemporary Interiors

Construction Techniques

Hull Every hull is moulded in a single piece using a method called contact moulding. Two-piece hull moulds are meticulously cleaned and prepared before the gel coat is sprayed onto the waxed surface.

Layers of fibreglass sheets are then applied with predetermined and specific quantities of resin. Each layer is rolled out to expel any air bubbles and the layers are built up in various thicknesses depending on the area and strength required.

The final composite hull is released from the split mould, the key benefit of which is that it allows for a pronounced flange onto which the deck structure is bonded. This flange creates additional integrity and strength for the hull to deck joint.

Structural Grid Laid inside the hull is a structural grid or counter mould. This enhances the structural characteristics absorbing and distributing the loads from the keel and rig. This grid also allows for a consistent position of the bulkheads and furniture and a clean internal finish for easy maintenance and cleaning.

Decks By contrast, the decks are made by a process called resin injection.

Layers of dry laminate are sandwiched between two moulds before resin is pumped in at high pressure to saturate the dry fibres. This ensures a totally equal distribution of resin to all areas of the deck.

Once cured this process creates lighter yet stronger structure which is free from imperfections and offers increased head room.

The hull is made up using a single skin layup and a PVC cored stiffener.

The rudder is a semi-elliptical shape with a thick structure to create a perfect grip, feel and balance. The shaft is stainless steel with a stainless steel frame encased in epoxy foa,.

Self-aligning rudder bearings are supplied from JP3 systems.

All the interior furniture is built in a dedicated factory in La Rochelle cut precisely by CNC machines.

Bulkheads are laminated directly onto the hull and the furniture is carefully assembled, fastened and bonded together.

The marine-grade plywood panels come in thicknesses between 12 and 18mm.

The interior side panels are made from Alpi engineered wood, perfectly replicating the patterns and grain of natural wood.

Alpi wood offers a hard finish resistance to humidity and UV

Then all around the boat, you will notice the generous use of solid wood frames and trims.

The varnish is used without any tint for fast and easy repair.

Floorboards are engineered laminate to create a strong outer coating for great protection from abrasion and scratching.

The galley and heads surfaces are all made from Corian which is a solid non-porous material that is highly durable, easy to clean and aesthetically pleasing.

Sailing Performance and Handling

• Performance hulls developed for safe offshore sailing 
• Stable hull shape with distinct chines to reduce heel
• High aspect rig design and fully battened mainsails
• Inclined boom for easy mainsail stowage and handling 
• Traditional layout with halyard winches on coachroof
• German mainsheet system for easy control of the mainsail
• Self-tacking jib traveler for easy sailing 
• Performance style steering wheels and pods 
• Optional overlapping headsails with adjustable Genoa cars
• Fixed bowsprits for  mounting downwind sails
• Balanced rudders that grip well even in rough conditions
• Torpedo keel bulbs improve righting moment and reduce drag

Interior Features

• Luminous and welcoming saloons
• Forward Galley – 430 and up
• Spacious and elegant master cabins
• Numerous cabin layout options 
• Solid wood finishing 
• Quality Fabrics 
• Corian countertops in galley and heads 
• Large Fridge and Freezer capacities 
• Optimised storage 
• Large wine cellars 
• Digital electronic control panels 

Exterior Features

• Large cockpit areas with long sunbathing seats 
• Wide side decks for easy & safe circulation 
• Closed aft cockpits for maximum seating and secure sailing
• Large easy to use bathing platforms 
• Functional cockpit tables 
• Integrated BBQ and sink on models from 360 up
• Helmsman backrest cushions for extra comfort at the wheel 
• Telescopic tender davits on some models 
• Premium bathing ladders with teak rungs 
• Deck and cockpit courtesy lighting on certain models 
• Premier cockpit and deck cushions

Wide Range of Options and Extra’s

• Performance Sail Packages
• Self Tacking or overlapping headsails
• Choice of engine options
• Standard and shallow keel
• 3 Interior Woodwork Options
• Natural Teak or Permateek Options
• Interior fabric options
• Electronics Packs
• Generator and Air conditioning
• Bow and Stern Thrusters

Simple, Effortless Sailing

Dufour Yachts have always been at the forefront of modern production techniques.  Continually evolving over the years, they are now established as one of the worlds leading boat builders with a range of yachts from 30 feet to 63 feet.

Benefitting from a long-established relationship with designer Umberto Felci, Dufour Yachts have created a modern range of yachts that lead the world in terms of performance, styling, quality, space and practicality.

Today Dufour operate a dynamic and successful shipyard producing over 400 units a year in its 18,000m2 facility. 

Discover more about Dufour and what makes todays range of yachts so exceptional. Universal Yachting are the UK Agents for Dufour Yachts.

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A Guide to Moscow: Capital of Russia, City of Domes

The Kremlin Dominates the City Center

Lars Ruecker/Getty Images

You say the word "Moscow" to Americans, and it conjures up the Kremlin, Red Square and images of intensely cold winters against the backdrop of colorful onion domes.

Moscow was Russia's capital before Peter the Great moved the capital to his new city, St. Petersburg , in 1712, and then again as the capital of the Soviet Union after the Russian Revolution -- the government was moved back to Moscow in 1918. 

Moscow never lost its intensity or spirit -- one that has inspired writers and poets, ensnared the nobility with its charms, and proved to be the center of Soviet mystique during the Cold War. Moscow represents both the Russia of yesterday and the Russia of today.

City Statistics

Moscow, as Russia's capital city, was home to more than 12 million residents as of 2015, according to the CIA World Factbook, and countless non-residents. While the population consists mainly of ethnic Russians, other groups are represented in relatively small numbers.

Moscow holds a top spot in the world's most expensive cities. The Russian capital is an international business center, and after the fall of the Soviet Union in 1991, international corporations have set up branches in Moscow . Industries like hospitality have risen to meet the need, ensuring that Moscow continues to grow.

Moscow is the seat of Russia's government, and the Kremlin , at turns an opulent and forbidding house of government, sits in the heart of the city. Just as the czars once ruled over Russia, so now does the Russian president. Visitors to Moscow today can see architecture that dates from 1533 to 1584, the reign of the first czar of Russia, Ivan the Terrible. One such building is the iconic  St. Basil's Cathedral , which is on Red Square and near the Kremlin in central Moscow. Through exploring these historic buildings you can gain insight into how Russia's way of life has long differed from that of the West.

Home to Russia's Greatest Writers

Russia's greatest writers were familiar with Moscow, and many lived in the capital city at some point during their lives. Some were born there, others died there, but they all left important traces of their lives for literary visitors to discover. Moscow is home to many Russian museums about its writers that seek to stop time for their greatest fans.

Center of Art and Art History

While St. Petersburg might arguably rival Moscow with its collection of art at the Hermitage, Moscow is home to the culturally significant Tretyakov Gallery . The Tretyakov Gallery is the world's most important museum of Russian art. Famous Russian masters -- Repin and Vrubel, among others -- have special places in Moscow's Tretyakov Gallery.

The Armory Museum holds a collection of jewels, crowns, thrones and carriages from royal Russia The Armory's State Diamond Fund preserves these important symbols of Russia as a czardom and empire.

Moscow is famous for its harsh winters that sometimes last until April. Summers are hot but not unbearable. Fall begins early, so the best times to travel to Moscow are from May until September. However, Maslenitsa takes place during February or March, so sometimes it's well worth it to brave the Moscow cold. If you're traveling there for Maslenitsa, check out these other  Moscow winter activities .

Getting Around

Moscow's metro system is fast and efficient. While its unforgiving crowds and system of stops might take some getting used to, it's possible to travel all over the city inexpensively and easily using the metro. A bonus: Moscow's metro stations are attractions in themselves. Opulently decorated in fine materials by master craftsmen, the Moscow metro stations are a unique and impressive aspect to Russia's transit system.

Staying in Moscow

Russia's capital city is expensive, and the closer to the center you stay, the more pricey your accommodations will be. For travelers on a budget, it's prudent to stay on the outside of the city and take the metro into the city center.

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Travel to Murmansk, the Largest City North of the Arctic Circle

This project is part of the thriving Moscow City mixed-use district—centrally located within the sprawling Russian metropolis—the design of which is similar to London’s Canary Wharf and Paris’s La Défense. An 85-story skyscraper and a 49-story office tower soar from a 7-story transparent crystalline base, gradually tapering away from each other as they rise. Designed by US-based architectural and engineering firm Skidmore, Owings & Merrill—renowned for its iconic towers, including Burj Khalifa, the world’s tallest building—the OKO Tower complex laid the groundwork for a new era in contemporary Russian development. At 1,150 feet high, and with a total area of 4,300,000 square feet, the OKO South Tower is not only the largest skyscraper in Moscow, but also the highest residential tower in Europe. The complex also has the biggest parking area in Moscow, with 15 levels for 3,500 parking spaces.

Residential and office lobbies have elegant interiors by Italy-based designer Massimo Iosa Ghini. With leading engineering solutions and security systems, 24/7 services, restaurants and bars, a private cinema hall, a luxurious spa and fitness center, and a private landscaped park, OKO Tower offers the ultimate in comfort and activity. The key-ready residential apartments boast designer interiors and stunning panoramic views of the Moskva River, the Vorobyovy Gory (Sparrow Hills) park, the Kremlin and the skyscrapers of Moscow City.

Open Days La Rochelle

The Dufour dealers are delighted to welcome you to the Port des Minimes in La Rochelle from March 13 to 16 on pontoon 1 to show you 4 iconic yachts from the range:

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16 Mar 2024 - 31 Oct 2024 Italy Spring Tour | Open Days

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