From 3D to reality, getting it right

While we have had the entire boat 3d modeled and designed prior to production of our molds there is nothing quite like sitting on the real thing and getting a feel for everything first hand. So at this stage in the development we have a dummy mast in place on our deck, and we hot glue deck hardware in its designed locations. Then, we re-enact the use of the boat going through various scenarios, different sails and different conditions to ‘feel’ how the systems work on a 1:1 scale. This has enabled us to maker small tweaks to hardware placement for the benefit of good ergonomics, and practical use of the 880.

#Corsair880 #880trimaran

880 production underway!

The first of our new 880 series has finally started production. With hull and deck now fully infused, we have actually begun weighing parts which are coming in per estimates and in some cases under estimated weights. This is part of our tight weight control program for the 880 model.  This positive news comes as a result of a last-minute decision to change our process to the more costly infusion process. This was done primarily as it delivers a far more consistent weight and structural result with a reduced carbon footprint due to the reduced emissions and consumable waste. We have also managed to optimize the deck laminate by replacing certain structural areas with carbon fiber instead of straight more commonly used e-glass. This gives us a carbon ratio of approximately 20% on this model resulting in a lighter, stiffer final product. Our first deck came out of the mold at just 166 kilograms, a good 11 kilo’s under our earlier predictions so positive news from production!

The last of the tooling components for the construction of the all-new trimaran Corsair 880 were completed this week.  That means molds for the hulls, deck, floats, beams, and all internal components are now in place.  The parts will now be repositioned to their choreographed production station, ready to start construction of the first Corsair 880 trimaran.

Shown here is the main hull mold, which gives the new model its advanced underwater shape.

The following images show the deck components – this gives the cockpit it’s broad shape, and the foredeck on the central hull.  That foredeck mold also reveals the place where the toilet will sit below deck, and the recess for the waste tank.

The black components are the internal parts for the Corsair 880 trimaran.  Shown here is the internal mold that reveals the shape underneath the settee.  And the next black part is the other side of the main hull – the galley.

Finally, the molds for the new aerodynamic beams are shown, along with the assembled beam.

Corsair is now embarking on a new stage of production as we build the prototype Corsair 880 trimaran.  So look out for exciting updates as the very first boat is built!

The busy Corsair Marine factory is full to the brim making multihulls.  So many of the key tooling components for the Corsair 880 are being constructed outside of the main facility and then shipped or driven in.  It was an exciting day today as the first of such components shipped out.

Seen in the first picture is the port half of the main or central hull mold.  Note that the tooling for this boat is supported by extremely durable and stiff steel framework – reflecting our intention to make every single boat to the same high standards, and have molds intended to match the long lifespan that all Corsair models should have.  It also means these molds are stong enough to be shipped, or moved frequently.

In the second picture is the foredeck mold of the main/central hull.   The large structures which here point upwards (the mold is “upside down” in this shot) are actually recesses for the toilet and waste tank.

Back in the Corsair factory, tooling work has begun on the masts for the Corsair 880.  Both mast options will be from Carbon Fibre – the Sport mast being 13.8 metres, and then the standard 12-metre mast.  Carbon masts offer obvious performance benefits, but also help keep the overall weight of the boat down, and make trailering, mast raising, and general handling of the mast an easier operation.  Seen in the 3rd photo below is the first mold for this crucial component.

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Werner, thanks for your expert advice.  Let’s get straight to the point (and this is the one that we at Corsair are most interested in!):  Why are Corsairs the best trailering trimarans?

Number 1, it’s the legal trailering width – which is achieved by the folding system. Much is made of the weight, but the width is so crucial because it is a number which is not flexible across many countries.  The Corsair 970 is 2.55metres width on the trailer.  Right at the legal limit.  The new Corsair 880 will also be within that number.  Many people have been stopped by police on our roads and everything is a waste if you fall foul of those rules.

Number 2, the boat doesn’t become longer when folded.  This makes big difference for maeuverability, but it keeps the total towing package within the legal length.  Other brands might just stay within the width, but you can still have a big problem if you have an accident and your length was illegal.

Number 3, the weight of the boat + trailer is crucial.  I carefully consider the weight of the boat before suggesting which material the trailer is made from.  For a Corsair 970, an aluminium trailer is almost a must.  For the other models, depending on the specification, it might be steel.

Lifting a Corsair Folding Trimaran with a travellift

The wind is blowing you off the dock

How about the Spars?

Again as we said about the total length, it’s important to stay within that number – usually 19 metres total of car+trailer.   Remember that before buying a racing mast – or at least talk to us about it.  And don’t forget that keeping the mast light is also important.  You need to be able to handle it manually, and load it up high. However the boats come with a yoke and all necessary equipment to handle the mast – including raising it.

The length of the mast is a consideration for trailering, as is the overall length of car + trailer.

The wind is blowing you onto the dock

What car do you really need?

Clearly it’s up to you.  But up to the Corsair 28 and new 880 there are a number of family cars that can tow the package.  Consider the additional gear you’ll carry, and look to your car papers.  The total carrying load of car + trailer might also be printed inside your door.  And it will be different from country to country.  Finally, consider that 4-wheel-drive (4WD) is extremely helpful when departing the ramp (in retrieving your boat from the water).  It’s not such a bing concern for the actual driving part, unless the conditions demand extra grip for some reason.  But 4WD is very helpful indeed when driving up a slippery ramp with a heavily-laden boat on trailer behind.  As such the BMWX5 with X-Drive (shown below) and the Land Rover Discovery have been very attractive for Corsair owners.

Towing weight is critical – as is 4WD for larger models

Do you always launch in the water from the trailer?  Or do you often need a crane?

I prefer the ramp. But the boats are also prepared to lift from the trailer by crane or large forklift.  In that situation the boat should be lifted by lifting the main hull only – don’t wrap the straps around the floats.  I don’t like compressing boats regardless of the quality of the construction.  All of the trailers I provide are marinized and ready to launch boats in the water on the ramp.  We use a brake washing system, and stainless steel brake systems so they are well protected from the salt water.

Careful consideration should be paid to the trailer construction material and brakes

Are the trailers single axel or double axel?

We use single axel up to the Corsair 760, and any models above that size use a double axel. Again, it’s worth talking to us about this early on.

Why don’t you trailer the Corsair 37?

Even I don’t have the car, or rather truck, to pull this boat.  With a Corsair 37 I suggest you consider having a professional driver. The trailers for such a boat are expensive.  So unless you’re changing your cruising ground frequently, it sometimes makes better sense to have a professional driver.

How safe is trailering?

It comes down to how you load your boat on the trailer.  Always use CE certified straps.  You should spend time with us loading and unloading your boat when it is delivered, so you know exactly what to do.  This is a useful service we provide.  The AA has a lot of information about trailering.  If you have their breakdown service its worthwhile notifying them that you have a boat on trailer.

A big point is to know your maximum speed allowance in all of the countries you’re driving through – it will be different from country to country.

You also need to have the correct signal and break lights, and in Italy (where a lot of my boats go) you need a special plate with the load striping (a form of signal striping).  We’ll make sure you are prepared for such technicalities and are kept safe on the road as much as we can assist you.

Final point on safety – it’s important to know the weight at the point of the ball on the hitch.  That capacity varies from car to car, and it’s something that we will look at when we know which car and boat you have.

Anything you would like to add?

You didn’t ask me about the maximum height.  That’s important for obvious reasons.  For example, when entering a petrol station.  That’s a situation that’s all-too-often forgotten.  Know your height.  The Corsair 970 is 3.6 metres.  That’s too tall for the passenger train on the Eurotunnel for example.  You would have to take the cargo train (which is a common occurrence).  You really must just know your height.

Read more:

Corsair 880 Design News

Folding Corsair trimarans: Legendary ability, unbeatable reliability

6th Annual Trimaran Sailing Clinic with Corsair