16 Canadian Yachting JUNE 2017impressively purpose-constructed space with several ventilated
enclosed booths for gel coating, laminating and preparing the
hulls, large open spaces for laying out the boats to be wired and
fitted, and a room for storing and inventorying the upholstery.
Unlike large-scale boat production facilities, there is no robotic
automation of the building process. High-tech materials are
used in the composition, but all of the construction is done by
hand to ensure quality and a dedication to the craftsmanship
that is deeply embedded in the DNA of Rossiter.
The construction process begins with the mold (each one
capable of producing over 600 hulls) being waxed and the colour
gelcoat applied. A barrier layer and a skin
coat of resin mixed with chopped fibres is
sprayed onto this, which enables proper
adhesion of the stitched mat materials.
Multiple layers of durable cloth with a
strategically oriented weave pattern is laid
onto this foundation and, using grooved
aluminum rollers, is saturated and affixed
(during our tour, this was executed by
Jonnie, a veteran boat builder who has
been with Rossiter for eight years, and his
apprentice). Moisture-resistant structural foams of various den-
sities and properties are strategically placed in the hull and
superstructure to provide a strong, durable laminate. Once the
stringer grid has been attached and the parts have dried, they are
carefully inspected and individually weighed to ensure quality. A
part that is underweight may be indicative of an incorrect ratio
of glass to resin or insufficient coating, whereas one that is too
heavy might compromise the durability of the hulls that they
aim to build, thereby reducing fuel efficiency and overall per-
formance of the boat over its lifetime.
At this point, the process for the rowboats and powerboats
diverges, with the nine types of rowboats
they build here going on to be finished
and the woodwork applied by Richard.
Using a similar hull to the powerboats has
made the rowboats slightly different than
the original models created by George
Rossiter in terms of lighter and more
durable hulls, but the functionality and
aesthetic have remained the same.
The powerboat hulls in turn are
moved to the next portion of the plant
where the stringer grid is mated to the
hull and the fuel tank and flotation foam
is added, after which the liner is bonded
to the stringer grid and hull to create a
single solid structure. After this, the
details are taken care of - the marine-
grade electrical wiring and plumbing (for
the Classic Day Boat and 23’ and 20’
models) is installed, collapsible deck
cleats with self-contained drainage sys-
tems are put in, and custom-made alu-
minum fuel tanks and windshields are
affixed. Teak decking is laid as necessary,
the rope or stainless rub-rails put on,
lighting installed, and all of the finishing
touches complete. Wherever possible,
Scott tries to use locally sourced services
In the glass shop laying up a new runabout. and parts with the upholstery contracted
Richard is a highly skilled woodworker
and boat builder and with his appren-
tice, Aiden runs the wood shop.