STUDIO 103 @Sand Sea and Air Interiors

Upholstery for Yachts, Aircrafts, Home, Hotels and Office


Leave a comment

Affordable cushion alternatives

CushionsReadytoGo

There are several cushion design options to offer a customer with a limited budget. The cushions shown here have butterfly corners, which resemble a boxed corner, but involve fewer fabrication steps, translating to a lower price point. This affordable and efficient solution allowed us to deliver a client’s project within an aggressive time frame.

Terri Madden’s May/June 2018 article for Marine Fabricator Magazine.
Check out Sand Sea & Air’s amazing work with cushions at SandSeaAir.com.

It is often challenging to offer successful cushion design solutions when a customer wants a champagne look on a beer budget. Getting the answers to the following four questions during the initial client meeting can make all the difference in finding an affordable solution that leads to a satisfied customer:

  • Who is the final decision maker? This may not be obvious, yet knowing this is critical to the success of the project.
  • What is the scope and time frame of the job? Perhaps the customer wants a full boat refit—and wants the salon cushions delivered in time for next month’s vacation. Can your production team meet that time frame?
  • What is the budget? This can be an uncomfortable conversation, but it is necessary. Knowing the budget up front will reduce customer frustration and prevent you from offering solutions that may be far out of reach.
  • What is the value of this project to your customer? Is it to resell the vessel at the best price possible with the least investment? Is it an upgrade after an insurance claim settlement? There are many possibilities, and understanding the value will help you offer the best solutions to your customer.

A recent challenge

Sand Sea and Air was contacted by a new customer who lives outside of Puerto Rico. He purchased a sailboat with large salon areas consisting of spacious seating on both the port and starboard areas of the salon. Hurricane María had damaged the vessel and he had thrown away 24 cushions and wanted new ones by the following month when the family was leaving for a live-aboard summer adventure down island. He had purchased the vessel at a bargain price and wanted new cushions at the “best price” possible.

Old photos of the vessel showed lumbar seating that was not reversible and held “in place” while out at sea in wavy weather. This usually involves several fabrication steps, which translates to a higher price point for cushions. The primary challenge was to tackle this job in the most efficient manner possible to provide an affordable solution and deliver the project within the desired time frame.

FoamDacronComboreadyforCover

Everything a project requires adds to the cost. For this customer, we included marine upholstery fabric, UV thread, medium-density polyfoam for the seats, and for the cushion backs we chose to utilize smaller pieces of stock foam triple-wrapped with Dacron®. Depending on cushion size, you might consider purchasing affordable bed pillows.

Assess the variables

We had our client review a checklist of options to confirm his priorities, such as tie-down solutions so that the cushions don’t go flying on bumpy seas. The checklist was our guide to effectively planning an affordable and winning solution that was within budget, comfortable, easy to maintain and secure.

Based on our customer’s request to fill spaces that originally housed 24 cushions, we devised a way to fabricate a single cushion in an hour. Doing the math with a shop rate of $100, his cost was already $2,400 without the cost of foam or fabric. This is why knowing your customer’s budget is crucial to planning, fabricating and delivering a profitable solution. We budget our proposals to bring the cost of goods within a margin of 35 percent. Assessing all these factors allowed us to design a cushion that provided durability, comfort and style at a reasonable price that was also profitable for us.

Plan your cushion lengths to the size of foam sheets available in your area for the least joins or waste. Theoretically, from a sheet of 55-inch by 75-inch foam you can get six seat sections at 25 inches by 25 inches or four seats that are 25 inches by 37 inches. Fabricating four longer rectangle cushions takes less fabric and time than cutting and sewing six square cushions. Additionally, fabricating only rectangle cushions for the seat cushions is a more affordable option than intersecting corner cushions with diagonal edges at each corner, which involve considerably more construction time. Reducing the overall quantity of seat cushions to a total of five long rectangles rather than the original 13 helped us keep the budget affordable. To secure the cushions on the vessel, we included a 2-inch band of Velcro® across the bottom of the cover prior to assembly.

Use the tips in this article to provide seat and back cushions with corner details that reduce fabrication hours and translate into affordable and attractive solutions for your customers.

Screen-Shot-2018-04-27-at-10.51.41-AMHigh style on a budget

Boaters want to sink into a safe and cozy spot to enjoy their time at sea. So why not create back pillows that offer the comfort of a bed, yet look classy for family and guests? Boxed cushions are the most widely used cushions for residential furniture and boats. They are tailored and frequently include a welt or piping with the boxing sewn to the top and bottom pieces of square or rectangular cushions.

However, a mock box cushion provides a lot of style for very little effort. It looks like a box cushion, yet it does not have the separate boxing strip. The fabric top and bottom pieces are measured and cut to include the area for the boxing, and corners can have a short seam or corner stitch to create a tailored, squared-off look. Other corner options include butterfly corners and Turkish corners (sometimes called a gathered corner). Similar to a box cushion, the mock-box cushion can include a zipper welt with a bit of practice.

MockBoxCushionMock Box Corner Prep

Image 1: To prep the basic cushion pieces, measure and mark with pins identical top and bottom pieces that are the exact size of the foam form (obtained from your pattern). On each of the four edges, add half the finished boxing depth. For example, the cushion foam form is 25 inches by 25 inches with a 4-inch boxing; this requires a 29-inch by 29-inch top and bottom piece for a cushion without a zipper, or add ¼ inch on edges where a zipper will go. Cut the two pieces, install the zipper, and then close the remaining seams, pivoting at the corners.

Squared-off corner

Photo 2: Separate each corner and ease open seams and align one seam on top of the other. Measure down from the corner half of the finished boxing depth, drawing a line across the corner, perpendicular to the matched seams; the length of the line should be equal to the finished boxing depth. Stitch securely across the line for all four corners. Option: Finish seams with a serge edge and/or topstitching.

ButterflyCorners1Butterfly corner

Photo 3: This corner is similar to the soft-box corner, yet it is less tailored and resembles a butterfly wing.

The corners are trimmed diagonally and then folded into inverted pleats. Measure in from each corner along the raw edge half the finished boxing depth. Mark these points and connect with a diagonal line. With the pieces together, cut along the diagonal line at all four corners. Fold to find midpoints along the diagonal, and mark these points with pins placed perpendicular to the diagonal edges. Separate the pieces with the right side of one piece up. At each diagonal cut, make two folds that meet at the center pin. Sew a tacking stitch to hold the folds in place and repeat at all four corners. Turn the cover to the right side and insert foam or Dacron® fill.

TurkishCornerCushionTurkish corner

Photo 4: Sometimes called a gathered corner, this corner has an exotic flair that is easy to make. Stitch the top and bottom pieces as described in the butterfly corner, and secure the corners from the wrong side. Start at one corner and measure from corner stitching along each seam line half the finished boxing depth. Mark these points on the fabric edges. Repeat on the remaining corners. Use a compass or small bowl to mark a curved line connecting marks on both the top and bottom pieces (eight curved lines in all). Put one hand into the pillow and reach into one corner “cone.” With your other hand, run a small gathering stitch (using strong double strands of thread) around the circle formed by the curved lines of the two pieces, opening the seams as you come to them. After encircling the corner, pull the gathered thread tight, wrap it around the gathers several times, and take a few tacking stitches to secure. Repeat at the remaining corners. Do not trim or cut the corner. Turn to the right side and insert foam or Dacron fill, working the filling into every corner.


Leave a comment

Selecting the best fabric

0318MF_CV2-13.indd

Photos 1 and 2: Designer and private label textiles, such as this Ralph Lauren anchor pattern, can cost $100 or more per yard. Using a matching tone in a solid Sunbrella® fabric on the zipper bands and bottom lining can help keep a project within budget.

Terri Madden’s March/April 2018 article for Marine Fabricator Magazine.
Check out Sand Sea & Air’s amazing work for marine environments at SandSeaAir.com.

Thank goodness for Dr. Google! When sourcing textile options for projects, fabricators can simply type in “marine fabric” and up pops a plethora of vendors and nautical-themed images. You’ll find individual maritime insignias that correspond to each of the 26 letters of the alphabet as well as graphic illustrations for almost every kind of nautical hardware—from anchors to navigation wheels. Also in abundance are fish patterns, playful sea horses and giant photorealistic renderings of marlin, swordfish and many other images that can be used on accent pillows, custom cabin quilts and pillow shams on larger vessels.

Budget for success

The initial discovery meeting with your client lays the groundwork for a successful project. Obviously, you will discuss the scope of the project, color palette, etc. But most importantly, you need to understand the client’s budget. Clients often avoid giving you a firm number, but moving forward without a sense of the budget can be a tremendous waste of time for both you and the client.

0318MF_CV2-13.indd

Photos 3, 4 and 5: Images such as flags and the nautical alphabet add dramatic flair to interior decor.

As you narrow your offerings down to a few key textiles that fall within your client’s budget, keep in mind that you can introduce a dramatic fabric as a focal point with as little as one yard of material. Using dramatic textiles makes a strong impression and helps ensure your position as a preferred fabricator. Check with your supplier about minimum quantity requirements, yardage availability and lead times.

It’s important to have a realistic sense of how much yardage is required for the items to be fabricated and to charge accordingly. For instance, an L-shaped sofa can easily require up to 14 yards of material. If your cost for material is $25 per yard plus a 50 percent markup, this translates to $525 for the fabric alone. Cost has to be taken into consideration if the project requires foam upgrades. Additionally, calculate the time and cost of removing the original material, fabrication of the new covers and the installation. And keep in mind that projects incorporating fabrics with patterns will require additional yardage.

At Sand Sea and Air, we use spreadsheets to calculate the material costs for each project, the fabrication steps necessary and the time each step requires. After we complete a project, we go back to analyze and record any changes that affect the final “true” costs and profit for each project. This system ensures we’re not losing money on a project and helps us tweak our budgets moving forward.

0318MF_CV2-13.indd

Photos 6 and 7: This pattern required us to balance horizontal and vertical repeats as well as a hinge fold in the bow cushions to accommodate the incline of the vessel. The final seams on the pilot and copilot seats reflect a harmonious transition, yet it was extremely challenging to fabricate the high/low back cushion in harmony with the seat cushions.

Tricky cabin tricks

Creating bedding for fitted mattress covers and cabin quilts presents specific challenges. Mattresses often have oval curves rather than a traditional rectangular shape, and you many need to work around framing that holds mattresses in place. Also, a master cabin bed is generally 60 inches wide, yet material is often available in 54-inch widths. To ensure you have sufficient material, it’s important to calculate and construct the additional sections on both sides of the center yardage with consideration to the pattern repeat on the top panels. I prefer to use the full 54-inch-width as the center and then use narrow bands of 4 to 6 inches of fabric on either side.
Additionally, side mattress bands can be as high as 10 inches, which means a good portion of the side bands will be visible. You will need to maneuver the fabric pattern repeat to get the most attractive part of the 54-inch width in the band front, with seams joining as needed toward the sides.

We recently fabricated fitted mattress covers for a queen-size bed in a Ralph Lauren anchor pattern. The material had anchors twisting left and right, some in opposite directions, while others were in the same direction along adjoining rows. Since this fabric was expensive, we used a matching tone in a solid Sunbrella® fabric on the zipper bands and bottom lining, as they would not be visible once the mattress was onboard. This helped keep us within budget and ensured a successful project.

0318MF_CV2-13.indd

Photos 8 and 9: It’s important to calculate the waste factor on side-by-side cushions when the visual pattern must remain harmonious. It can be as much as 14 inches, as was the case in the Kravet® Turquoise Flamestitch pattern with a 17-inch height repeat. Fortunately, that was exactly the height needed for the upper back cushions. We darted the excess fabric in the center of the curved corner cushion so the sides maintained the continuous visual repeat of the pattern. We also manipulated the fabric along the sides and back of the bow headrests to continue the dramatic pattern seen on the front of the cushion.

As you fabricate the details of your projects, imagine each one as a winning entry in the Marine Fabrication Excellence Awards. Careful planning and execution will create a complex masterpiece that embodies more than form, fit and function for your customer; it will provide the personal satisfaction of a job well done.


Leave a comment

Preparing for disasters

ClubNautico-SanJuan

Hurricane Maria damage at a marina in San Juan. A metal roof structure collapsed
on the boat of one of Sand Sea and Air’s customers. Photo: Alayna Wool.

Terri Madden’s January/February 2018 article for Marine Fabricator Magazine.

Editor’s note: Like many people who live and work in Puerto Rico, longtime contributor Terri Madden, owner of Sand Sea and Air Interiors Inc., has been deeply affected by the hurricanes. We asked her to write a column to help others learn from her experience.

When a disaster occurs, everything takes on a new meaning. The essential needs of food and shelter become primary not only for ourselves, but also for our loved ones. With world news at our fingertips, we read daily about tragic circumstances affecting both strangers and people we know. So…do you and your family have a disaster plan in place? Do you as a business owner have a contingency plan for your employees as well as your facility? If the answer is no, I hope this column will propel you to action. You never know when a disaster will strike.

The new normal

As I write this from Puerto Rico [Oct. 30, 2017], more than three million people are still in survival mode. It has been 41 days since one of the world’s strongest hurricanes on record made a direct strike on the “Enchanted Island.” Nine hundred and eleven people are confirmed dead and our borders may be closed indefinitely due to bacterial contamination or yellow fever epidemics. Airplanes carried more than 73,000 people to the mainland so far and airline tickets are currently sold out for at least three weeks. Electricity has only been temporarily restored to less than 10 percent of the island.

I am fortunate that my home and business were not completely wiped out. I have declined offers to “go somewhere” because Sand Sea and Air has employees and customers who depend on us. These days I am in survivor mode and I am not alone. Several other U.S. fabricators’ homes and businesses were also affected in 2017 by fire, flooding, snowstorms, hurricanes and tornadoes. Some were left with only the shirts on their backs, while others fared slightly better but are still dealing with the aftermath of a crisis, trying to pick up the pieces and plan their next steps.

Where to start

Ask yourself, if you had to quickly flee your home or business, what would you take and how easily could you let other things go?

Look around and evaluate your belongings. What would you put in your car or suitcase? Your pets, photos, a computer, documents, a few clothes, a passport, a cell phone? What could you leave and drive away from with a peaceful heart? Pause for a moment to evaluate and scale down your essential belongings. Get clear on your priorities!

ImportanceofSupplierSupporttowardRebuilding

Donations are critical for rebuilding damaged homes across the island. Shade sails and hardware donated by IFAI-member Wholesale Shade, San Marcos, Calif., will cover the new framing of this home. Photo: Alayna Wool.

Keep your business viable

Once the immediate hours or days of tragic events have passed, you may find that circumstances present themselves to strengthen you. Hopefully, you are better off than others and can lend a hand that will bless you twofold. But, if finding basic necessities like food and shelter is all you can do, then hour by hour pick yourself up.

At Sand Sea and Air, we worked the first five weeks by propane lantern light and wore bicycle headlamps to pattern and prep materials for current orders. We set up a temporary mobile office nearby in a facility with a generator.

We are still working on laptops to plan our next steps and keep batteries charged. We vacillate from frustration to a sense of accomplishment when we achieve even just one task in a day! Orders have been forthcoming as customers try to jump-start their lives and ask us to replace missing, broken or deteriorated items. I like to believe that we are better off than most, yet I can’t help but wonder at times.

The immediate aftermath

Short-term actions

Be grateful if you are able to stay in your home or with family members or friends as you gradually pick up the pieces. We are accustomed to multitasking and doing things on deadline. When we are forced to a standstill, it can be extremely frustrating.

  • Contact your family, friends and employees.
  • Take photos of all damaged items and areas before doing any cleanup.
  • Assess damages and obtain estimates for replacements or repairs.
  • Contact your insurance company to file claims on personal property, vehicles, your business, etc. (You can be reimbursed for the contents of a home refrigerator up to $500 with no deductible.)
  • Seek help from the Federal Emergency Management Agency (FEMA), which offers an almost immediate relief payment ($500) deposited directly to your bank account for individuals who have had to leave their homes during a disaster. You can apply at www.fema.gov.
  • If necessary, contact the Small Business Administration (SBA), which offers low-interest loans to businesses affected by disasters.

Picking up the pieces

Long-term actions

  • Establish a support network. Delegate one or two people to contact others. Keep distant family members and friends in the loop so they know how to help you.
  • If possible, post updates on Facebook or WhatsApp to reach others quickly when you can’t connect individually.
  • Let business associates know what you may need—they will want to help.
  • Set up links to GoFundMe and other crowdfunding sites.
  • Connect with organizations that offer help with small and large issues, including religious organizations, community groups, clubs, etc.

Help from IFAI, vendors and suppliers

In the hurricane season’s aftermath, sales reps and vendors such as Mike Hendricks at Keyston Bros., Derek Robinson at Glen Raven, Mike Sandercock at Quality Thread and Notions Company, Gregg Burrows and Patrick Howe at Wholesale Shades, Craig Zola at Herculite® and Greg Smith at Million Air have reached out to us offering assistance with discounted pricing, product care packages and samples. IFAI kindly posted an update on our situation in a member email news brief.

Ultimately, it is God, amazing friends, family and the encouragement of other IFAI members who are the web of support that gives me the energy and strength to survive. My heartfelt thanks to all of you!


Leave a comment

Foam failures and how to prevent them

Moldy Mattress Liner & Foam 2 copy

Exterior mattress that sat next to a Jacuzzi. An exterior mesh cover over Dri-Fast® foam could have prevented the deterioration of the vinyl cover over polyfoam. Stagnant water grew mold and the seams allowed the water and mold to seep into the polyfoam.

Terri Madden’s July/August 2017 article for Marine Fabricator Magazine.
Check out Sand Sea & Air’s amazing work with foam at SandSeaAir.com.

All marine fabricators who provide products for cushions, bedding and headliners face decisions on the best foam for the application. The right decision ensures quality projects and happy customers. The wrong decision contributes to foam failures.

Cheaper can cost more

Less expensive foams may seem like a good deal until you realize they can deteriorate far more quickly than pricier foams because they may include fillers and additives such as sawdust and soybean oil.

I saw this firsthand some years ago during the oil crisis when prices for petroleum-based products (like foam) shot through the roof. One supplier offered a less expensive marine foam that was not yet “captain” recommended—a definite red flag. Two years later we were contacted by a new customer to replace the deteriorated foam from that supplier.

Hi-LoFoamDeterioration

Here is one situation where a liner may have diminished the effects of sunlight. This image shows a commercial acrylic material on an exterior cushion where the polyfoam shrunk in the areas where the fabric was the lightest color. Interestingly, the foam was not affected where the dark stripes absorbed the sunlight. Photo Credit: Devin Genner

To prevent this sort of foam failure, only deal with reputable foam suppliers, ask a lot of questions and educate your customers who may not immediately understand why a more expensive foam product may be more cost effective in the long run.

Case study of cheap foam breakdown

A five-star resort hotel asked us to replace exterior cushions and daybed seating that were only two or three years old. One of the cushions looked like a former balloon that had been popped, another looked as if a wild dog had chosen it for a nesting spot and a third looked as if it had gastric bypass surgery!

Fortunately, we had not provided the original cushions and it was obvious the failure was due to a “budget” foam. A quality marine foam would have lasted twice as long. These cushions did not have liners—only exterior covers in an outdoor fabric.

Fabric liner considerations

Would a liner have prevented this issue? I don’t believe so. This

Lounge Seat Foam Shrinkage

This exterior daybed foam was one of several similar pieces at a resort property. It was a shocking example of foam shrinkage when inferior marine foam was supplied by a low-budget vendor.

was clearly a case of the cellular structure of the foam deteriorating in a commercial setting where the seating was used more frequently than on a private vessel. Fabric liners can prolong the life of exterior cushions in some marine settings, but there are important things to consider when using them:

  • Fabric type: Some liner fabrics are magnets for mold and mildew when used in an exterior application, and this will also affect the underlying foam. If a liner material is used, make sure it is mold and mildew resistant.
  • Application: If frequent cleaning will be required, foam placed inside a liner makes it easy to remove and reinsert into an outer cover.
  • Foam type: I generally always use Dri-Fast® marine foam here in the tropics where exterior cushions are frequently subjected to moisture. However, manufacturers offering water-resistant fabrics often question the necessity of using marine foam with their products. If your customer is on a tight budget and will be storing the cushions indoors when they are not being used, you might be able to use a less expensive foam.
Wet Seating under Cover

Asked to replace these old bow cushions, I was surprised to see how wet the cushions were underneath a protective cover that did not appear to be torn or broken. To prevent this, a water-repellent finish could have been applied to clean cushions at the first sign of water seepage. A breathable, water-resistant cover would allow for water runoff.

Good cushion foam choices

Open-cell reticulated foam has extremely open pores that allow water and air to flow through it easily and is available in soft, medium and firm densities. These foams are comfortable and stay cool when used for seating cushions and mattresses. Dri-Fast (sometimes called marine foam) is a high-quality open-cell reticulated foam formulated with an antimicrobial agent to prevent mold and mildew. When paired with an outdoor cushion fabric for the top and sides with a mesh base, it creates a virtually maintenance-free all-weather cushion that is easy to clean without removing the foam, making it an ideal choice for most boat cockpit cushions.

Closed-cell PVN foam (also known as flotation foam) is three times firmer than polyurethane foam and is a more expensive option. Its buoyancy makes it a great choice for flotation applications like floating cockpit cushions and life vests. It is also a good choice for commercial boat seating or other seating that will be used as a step for getting on and off the vessel. PVN foam resists water absorption, so you can safely cover it with any type of fabric. Thin sheets of closed-cell foam are often glued to the bottom of other foam, adding additional support to a cushion, like a box spring to a mattress. When using it with Dri-Fast foam, cut holes in the closed-cell foam for drainage.

Supposedly Marine Foam Breakdown

These two-year-old exterior cushions were provided by a well-known manufacturer. Perhaps budget constraints determined the use of polyfoam and the fabricator thought a water-repellent liner would keep water out. Verify the specifications of the materials you use to avoid this situation. We omitted the liner and used Sunbrella® fabric with Dri-Fast foam.


Leave a comment

Seating solutions for reclining, storage and temperature control

IMG_6101.JPG

Terri Madden’s March/April 2017 article for Marine Fabricator Magazine.

When a customer requests an unusual type of seating for a boat, it’s a fabrication opportunity to begin a comfortable dialogue with that client. Instead of hesitantly saying, “I will try to do my best,” turn your response into, “I am here to help you.”

That customer may have already heard a reluctant fabricator say, “That’s not possible,” or “That’s going to cost a lot of money.” The open-minded fabricator will thoughtfully listen and ask questions as the customer describes his or her vision. The goal is to cultivate a constructive dialogue that will help a customer understand the value of the fabricator’s time, effort and skills. What’s more, creating an especially challenging seating project may become an award-winner that ultimately showcases a fabricator’s considerable skill and experience.

Customers are often looking for a wow factor in their new marine cushions and seating. At the same time, they usually have budget constraints and want the work completed as soon as possible. To balance these demands, fabricators need to help clients understand the give and take of turning unusual requests into reality.   

When an usually project is requested, here are ideas for preparing for your first meeting with the client:

  • Designate a day to review his or her request so you have sufficient time to explore solutions that will suit the project.
  • Consider whether this project will take away or add to your core business.
  • Review measurements and gather photos of similar projects.
  • Develop sketches and rough drafts for the client.
  • Research the type of materials required, including quantities, costs and availability.
  • Compare the customer’s budget to your rough estimate for materials and labor.
  • Designate your prototype fee in your estimate; this will be different than a quantity fee and re-orders on certain items.

Adjustable chaise seating

Consider what new projects you have seen in the past year. I find it inspiring to view fellow fabricators’ projects that, to my knowledge, had not previously existed in the marine market but are now are frequently seen on pleasure crafts around the world.

Adjustable reclining chaise seating has been in the furniture industry for years, yet only recently have a few fabricators sourced hardware and materials to transition this idea to the marine market. Now this comfortable solution is a reality for marine customers.

In the past, super yachts often incorporated flat cushions into a recessed area on the bow of the boat. Typically these “day bed” cushions have had elevated headrests integrated into the body of a cushion, providing only a few inches of elevation. However, fabricators like David Elliott, owner of David’s Custom Trimmers in Australia, have recently utilized a 25 mm Kingboard as a custom base with a stainless ratchet-hinge. The hardware is available from Taco Marine. This fusion has provided a durable and comfortable solution for guests to sit side-by-side with one person relaxing in an upright position while another person reclines.

Since the completion and installation of this project, Elliott has been sourcing additional prototypes for alternate functional hardware that is enduring and functional when installed into a fiberglass hull. He, like so many other fabricators, continues to strive to propel a great concept to the next dimension.  

Premium storage

Every vessel, no matter how large or small, needs optimized storage space, which is always tight onboard. Crew and owners need most items to be securely stowed away, yet they want easy access to everything from hardware to comfortable quilts.

Clever storage was recently created in the armrests of a custom-built sofa by Canvas Designers Inc., Riveria Beach, Fla. In fact, this upholstery project was awarded an Award of Distinction in the MFA 2016 Fabrication Excellence Awards. This custom sofa was for a 72-foot Merritt Sport Fish.

The two sofa arms of this handsome U-shaped sofa provide spacious custom storage via a hinge access feature. [Terri, this project was included in the March/April 2106 issue of MF (MFA Fabicator Awards). It stated “The entire seat and back are on hydraulic hinges, which lift up for storage space.” I think I should add this.]

Pat Erickson, at Canvas Designers, says the company slogan is, “If you can dream it, we can make it.”

The sofa is all leather with the back sections custom built with 2.25-inch horizontal channel pockets. The foam pockets were individually fabricated with a Stamoid back base for stability. The back has zipper access for stuffing the foam into the individual pockets. The size was specified by the client to match the leather boat blinds. This custom feature on the sofa back was exactly what the customer envisioned.

Just last week I received a customer request to include armrest storage in new custom sofa on a family vessel that is in a full refit stage. The customer saw this feature on the Internet and at a boat show. This opportunity illustrates how important it is to keep up with design trends for seating and cushions through Marine Fabricator magazine, seminars and conventions.

Climate controlled seating

Bill Marriott from Extreme Upholstery Designs, Charleston, S.C., is a talented fabricator who recently exceeded a customer’s expectations by creating climate-controlled mezzanine seating. He described the request as a “brain teaser, to say the least.” He puzzled through every step before preparing a prototype. Many times this type of process can take a fabricator days or weeks. I like to call it “chewing over a project.”

Bill’s client flew him to the boat site, so he could pattern the seat area on a new custom-made 62-foot Scarborough in North Carolina. The resulting seats are climate controlled with heat and air conditioning, so the owner can have a cool ride after a long hot fishing trip. Sunbrella® fabric was used. The one requirement the client had was, when standing on the dock or the back of the boat, he did not want to see into the open holes where the heat and air comes through the seat. Bill designed the seat so that only the fabric was visible when looking at the openings.

This was no easy task for a three-dimensional seat, which required access to insert the foam on form fitting cushions. Talent, ingenuity and years of design skills were incorporated into this amazing creation   .

Here are preparation tips that can guide you in creating a challenging project.

  • Do a conceptual “walk through” for each stage of a unique project to ensure that your time and talent are adequately compensated.
  • Confirm materials and hardware.
  • Prepare a maquette, sample or pattern.
  • Consider contours and alignment of all areas.
  • Determine time factors for each stage.
  • Determine what employee training may be required for the project.
  • Determine installation logistics and storage-related issues.

Don’t be shy about calling on fellow fabricators for advice when you hit a roadblock. You will be surprised at how willingly they share resources related to suppliers, techniques and professional contacts. I recall reading about scrim foam in the Marine Fabricator magazine several years back, I did not know what this foam was or how it would be utilized, so I contacted the author. She was more than willing to explain the various types and usages and provide a list of vendors. Through reaching out to others, I am fortunate to have many friends in this unique industry.


Leave a comment

Meticulous prototyping leads to attractive cylinder cushions

screen-shot-2016-10-21-at-9-35-59-am

Terri Madden’s September/October 2016 article for Marine Fabricator Magazine.

You can browse the PDF, or read the text version below.

Approaching a project with cylinder cushions is kind of like trying to put a square peg into a round hole, you have to approach the solution by thinking “outside of the box”. The box being what we are familiar with when constructing cushions – foam in rectangular shapes, cushion covers with standard size side bands and upper and lower faces of equal dimensions. Ok, so you’re starting to get the picture, or you’ve visited a job site and been requested to fabricate cylinder cushions; all of the sudden you’re walking on uncharted territory. You can approach the challenge by welcoming it as a learning opportunity and break down the stages into manageable sections. If there are multiple pieces, you’re already a step ahead as fabricating more than one piece will add to your profit ratio.

Over the years we’ve been asked to fabricate several unusual items that may or may not be a product that we have no way of knowing if it will be a “one hit wonder” or an item that will “take the market by storm”. A while back we started charging a prototype fee, a few hundred dollars to develop and fabricate a concept for a customer, a prototype then goes to a set price based on the final quantity. We consider the customer and this price sheet found on the Internet:

Price List

I design everything – $100

I design – You watch – $200

I design – You advise – $300

I design – You help – $500

You design – I help – $800

You design – I advise – $1300

You design – I watch – $2100

You design everything – $3,400

This pricing may or may not apply to your project, yet do consider the learning curve if you’ve never fabricated a cylinder that will attach to tubing. I recommend setting aside several hours of uninterrupted time to develop the concept and fabricate prototypes in order to evolve the best solution when you do not have a pattern or a good existing cover that you can take apart for your project. When you build this factor into your project, the understanding that you are being compensated for your talent, will inspire your solutions and result in an award worthy project.

If the customer wants to use existing cylinder foam, evaluate how the foam shape has conformed to the original covers and if at all possible, move forward with new foam. This is very important as the old foam may need a topper in order to properly “fill out” a new cover! You can order dry-fast foam cylinders, cut to size, available in three densities of firmness, including the cut-out for the tube in the cylinder center. On the illustrated sketch you can see the diagram we submitted when we ordered new foam from Reliatex Inc. They have facilities in Jacksonville, Tampa and Miami, Florida. Be sure to allow sufficient lead-time for any supplier to cut and ship your product.

Getting Ready to go for the Gold

Ok, so now you’ve analyzed the task, the quantity and style of cylinder cushions, and determined a price that you and your customer find agreeable.

When we measured the original cylinders we realized that they were all slightly different lengths and that one standard size would work well within the tubing frame spaces. Additionally, a standard size would be less production time vs. custom sizes and the overall project would be more visually appealing. We include an extra 1/2″ more or less for our finished foam size (based on the foam density) when ordering new foam, so that the foam “fills out” the cushion cover.

As the actual time for fabrication approaches, having the foam cylinders on-hand is essential for proper pattern placement and achieving the best final fit.

For this project we approached the cylinder design and prototypes without an original pattern, since the original covers were not the quality that we would replicate. Now our basic guidelines were our roadmap to reach our goal to design and fabricate tasty cylinder covers to fit over the stainless tubing; cylinders with an 8” diameter and a length of 27”. It was now in our hands to make removable covers for 4 cylinders with inserts in medium density foam, which would provide sufficient for firmness for seat backs so guests could enjoy relaxing moments while at sea.

In the past we fabricated jacuzzi pool cushions on tubing that helped us in our approach for this project. The jacuzzi cushions were designed for a more permanent location, whereas the cylinders for this project needed to be removable by the crew on a 42’ catamaran.

Our Solutions

  • We started with the round ends first. The circles were cut to include a 1/2″ seam. We cut two – 8” circles of vinyl for each side. We generally cut our foam and material the same size in order for the foam to “fill-out” the cushion cover after the seam allowance reduces the cushion size.
  • We placed the vinyl circles face to face.
  • On the inside of the vinyl we marked the center hole for the tubing cut-out and a line for an opening along 1/2 of the diameter for an access opening, when the finished cylinder would need to be placed over the tube.
  • We stitched along outside of indicator line for the opening slit, around the circle for the tubing and down the other outside line for the opening slit.
  • We cut next to the stitching between the lines for the access opening and around the center hole – removing the excess at the center hole.
  • We turned the layers to the right side and top stitched the layer opening “in place”. Then we trimmed the inner facing layer as seen in the photos.
  • The cylinder ends would secure closed with a Velcro flap whereas the center of the cylinder would incorporate a #5 jacket zipper. The tails of the jacket zipper would hide inside of the sides of the cylinder and be accessed via the Velcro opening and closing next to the tubing.
  • A piece of 2” Male Velcro formed the flap as one edge of the Velcro was sewn to one side of the opening under the tube hole and a piece of 1” Female Marine Velcro was sewn to the other side of the 4″ opening. This insured that the area would hold tight in a closed position when the cylinder was placed on the tube. See photo.

I’ve included a few photos of the Jacuzzi cushion that was made with the zippers extending into the side ends showing the stitching sequence & pole placement cut-outs, which were underneath of cushion zipper.

  • The cylinder center was measured and cut with seam allowances included for the zipper.
  • The two ends of the cylinder were sewn to the center panel
  • The jacket zipper was sewn to a turned edge of the center panel, leaving a 3″ tail at each end, where the cylinder side ends met the center panel.
  • The foam was inserted into the cover (we spray a dry silicone when inserting foam into covers, as it reduces the resistance of the foam and material).

I included photos of a unique striped canvas cylinder project that we observed on a vessel, cushion covers definitely in need of replacement, yet the vessel was not in San Juan for the project to be realized.

The finished cylinder could be easily placed on the tubing, inserting the foam over the tubing, closing the zipper (tucking the zipper ends into the foam and securing the end circles via the Velcro. By carefully maneuvering the foam at the cylinder ends the male and female Velcro would secure/close the space below the tubing to where the zipper connected. The end result was sleek cylinders with hidden access areas for easy removal and installation. Additionally, at the time of installation we wrapped the tubing with nonskid to hold the cylinders “in-place”, as the original cylinders had unsightly zippers, which displaced to various locations on the tubing.

Not only were we proud to deliver a handsome project, the captain and owner were equally pleased. The design and fabrication process is in our library of cushion styles and will certainly be a valuable example when the time comes to reproduce cylinders that fit into and on special spaces that require Stylized Solutions!


Leave a comment

The art of project management on contour cushions

Screen Shot 2016-07-13 at 9.14.14 AM.png

The horseshoe-shaped seating for an aft cockpit required an elaborate checklist to ensure that all the customer’s requests were fulfilled.

Terri Madden’s July/August 2016 article for Marine Fabricator Magazine.

You can browse the PDF, or read the text version below.

Marine fabricators are a unique group of craftspeople and business owners. Many of us are familiar with the notion that creative pursuits are right brain activities, while math and logic are left brain activities. As marine fabricators, we utilize the right sides of our brains for design solutions that meet customers’ aesthetic and practical expectations. At the same time, we utilize the left sides of our brains for business activities like managing shop operations, doing complicated mathematical calculations, and making sure that all project specifications are completed.

The two sides our of work come together through good project management skills, so each person on the team knows what he or she is responsible for and the corresponding deadlines. My business has been fortunate to have an inspiring coach who repeatedly stresses, “Any project that we don’t plan will take us to hell!” Most fabricators would agree with this motto.

Screen Shot 2016-07-13 at 9.25.38 AM

Sketch and measurements for seven seats and four bolsters

Screen Shot 2016-07-13 at 9.27.53 AM

The pattern for the cockpit cushions

Screen Shot 2016-07-13 at 9.27.32 AM

The side view and front view of a single aft seat

Detailed spreadsheets

We use an Excel spreadsheet to list the job details from start to finish along with realistic timelines. The details we include are:

  • Travel to the job site.
  • Patterning at the vessel with all cushion perimeters marked and all identifications noted as well as photos.
  • Materials needed. If necessary, include your research time to identify customers’ preferred choices. Check for stock items, submit purchase orders. Follow up with local suppliers or on items being shipped.
  • Production card planned with name of team member(s) and their respective tasks and processes.
  • Team review with photos to discuss scope of job, time frame, and assigned tasks.
  • Examine the patterns for all necessary indicators such as notches, zippers, seam joins etc. For the project described in this article a non-skid backing was included.
  • Layout diagrams for materials and foam.
  • Cutting directions for material.
  • Sewing details, including any training, if required.
  • Inspections and daily review to insure accuracy and timing.
  • Foam cutting and Dacron toppers.
  • Foam inserted into covers.
  • Inspection of new cushions before delivery
  • Transportation and installation at vessel.
  • “After” photos to post on Facebook, other social media sites and newsletters.
  • Job review with team members

Reviewing this list of everyday responsibilities can be eye opening. Depending on the size of your business, you may have separate personnel handling these tasks, or some employees may have multiple tasks.

Verify that all of the details are noted on the final pattern, to insure that each component of your project will be delivered in a timely and profitable manner. As you know, any forgotten detail will cost you time and employee frustration.

Screen Shot 2016-07-13 at 9.34.12 AM

6-7. Early and final patterns for a single seat cushion. 8. Notched contour area for accurate joining of top and bottom faces. 9. Bottom face with non-skid fabric and zipper installed.

Planning sleeker contour cushions

A recent fabrication project involving contour cushions for a 43-foot catamaran drove home the importance of project management. For this seating project, the scope and sequence of the project was complex. By thoroughly detailing every aspect of the job, I could accurately project the time needed for the production schedule, including the purchase of materials.

Our creativity was unleashed on this project as we experimented with a sleeker contour for the new catamaran cushions. The captain of the vessel had forwarded sufficient details with an area layout along with material preferences and requirement dates. That was enough information for us to provide an estimate.

We commenced to pattern the horseshoe shaped seating of the aft cockpit, which we learned is the most used seating area of this vessel.  We prepared a checklist to review with the captain during our visit to confirm the details for the following:

  • Cushion design. See sketches and final pattern indicators for a sleek contour at tubing locations.
  • Total number of cushions.
  • Materials for top and bottom material.
  • Thread type and color, topstitching details.
  • Zipper color, size and slider location. We like to place slider tabs on the inside for cushions that won’t be opened frequently.
  • Foam type and density.
  • Dacron toppers.
  • Nonskid base.
  • Piping, ties, snap tabs, Velcro and other components.
  • Starboard base. For the captain seat we supplied a new ½-inch panel of starboard.
  • Bolsters and accent pillows, including quantity and sizes.

All of this information was used as the guideline for filling in our job spreadsheet. We entered all data and updated the spreadsheet for a final accurate job cost. Keep in mind that job sheets can act as templated guides on future projects; we can tweak similar spreadsheets for new projects with just a few changes.

We include the following:

  • All job materials.
  • Separate pricing for all components and percent mark up.
  • Quantities.
  • Shipping costs.
  • Task times for each phase (total labor hours) for a final accurate job cost.

After the seating project was started, the boat owner requested the patterns with the job. In the past we have been asked to retain patterns, and we keep a 2 percent inventory of material in case the owner needs an emergency replacement. Currently, many projects are digitalized and it is easy to maintain or provide a duplicate for any item. Company policies vary for storing and providing job patterns. Terri, what is your policy? Only one design co has asked us to retain patterns for  1 year.

Screen Shot 2016-07-13 at 9.34.21 AM

10. Inside view of notch indicators at contour and zipper detail. 11. Outside view of cushion at a corner contour for tubing and topstitch detail to hold seams in place. 12. The first step involves sewing the outside edge of the zipper tape to the inside of mesh. 13. For the second step, on the outside of the mesh, cut open the mesh along zipper teeth. For the third step, fold the mesh toward the tape edge and top stitch.

Encouraging your employees 

Project management includes encouraging and coaching your employees. Shop owners and managers need to ensure that employees have the skills to thrive under pressure, and that requires communication, training, and recognition. We need to cultivate new employees by exposing them to small projects where they can gain confidence. All employees, no matter what their length of service, need to be recognized for their skills that result in a well-executed project.

At the end of a project, ask your employees what their biggest learning experience was. Point out aspects of the work that you appreciated. Build on their strengths and coach them on their weaknesses. It is essential that team members feel satisfaction for contributing toward a successful project.

Screen Shot 2016-07-13 at 9.50.27 AM

14. Don’t be fooled by the clean look of new cockpit cushions; the elegant outcome is the result of detailed planning and execution.


Leave a comment

Elegant performance in stripes

Screen Shot 2016-06-29 at 2.48.47 PM.png

Terri Madden’s March/April 2016 article for Marine Fabricator Magazine.

You can browse the PDF, or read the text version below.

Stripes come in every color, shape and size…a two-color stripe can even be juxtaposed to form an eye-catching pattern. Striking stripe patterns can be matched or combined with solid colors to provide dramatic effects for your next project. Stripes are more popular than ever and Sunbrella likes them so much that they featured subtle as well as dramatic stripes on their 2016-2017 Upholstery Fabric Brochure. Stripes can be placed horizontally or vertically to give a low and wide effect versus a high or tall dimension to a space. As Marine Fabricators, we even get to play with stripes around curved edges and contour corners. The sky is the limit, yet we need to apply some earthly planning to ensure that incorporating stripes into a project is a winning solution.

Every year new patterns and colors are developed that invite fabricators to create different looks on board a yacht; classic, modern, chic or sophisticated. A sailor stripe sets off an eye-catching look, especially when combined alongside various shades of brilliant oranges or you can offer a subtle pallet of clay and charcoal that is a modern interpretation of European inspired designs with architectural precision.

If you’re not familiar with fabricating with stripes it can be a bit of a challenge, yet you can welcome the opportunity, as stripes are synonymous with boat décor and make a dramatic nautical impact on any yacht and your choices of colors and sizes are endless.  I was a bit daunted as to how to proceed for a few of the projects and spaces that will be explained and illustrated in this article. I want to give you that ‘step-ahead’ when your next customer inquires and selects a striped marine textile for their boat. Some essential design elements for you to consider are the following:

The Repeat of a Fabric

The repeat of a fabric refers to the number of inches it takes before the pattern starts all over again. It is the distance between the starting point of the pattern to the point where that pattern starts over again. This is referred to as “one repeat.”

Screen Shot 2016-06-29 at 2.49.09 PMWhen choosing a fabric for a project, it is important to know the repeat of the pattern you are considering.  The repeat can have a big impact on how much fabric you need, and what that product looks like on a sectional seating with multiple cushions compared to a single cushion.

Any type of patterned fabric will always have a repeat, and the supplier generally provides this information.

The average repeats size of a stripe is between 8” and 9″. A cushion layout needs to be planned ahead of time, for ordering the correct quantity of fabric as well as the best use of the material.

Recently we provided a few color ways to a customer in a handsome nautical stripe. We received two swatches from a supplier of the nautical pattern below; one was a navy/white/tan color way and the other was a teal/white/navy color way. The customer selected the navy/white/tan color way and when we went to order the material we were told that the pattern repeat was 16″. Ironically the teal/white/navy color way was a continuation of the navy/white/tan color way, yet with several more white stripes, which our customer did not want. Additionally, the 16″ repeat would have been extremely difficult to pattern as well as a significant amount of fabric waste for matching cushions that would sit “side by side.”  Below are two swatches sewn together to show the full repeat!

Screen Shot 2016-06-29 at 2.49.23 PM

16″ Fabric Repeat

Also, it is always wise to have your customer select not only their first choice of material for a project, but also a second choice as time between fabric selection, confirmation and you ordering materials may result in your customers #1 choice not being readily available.

Location

Determine the cushion(s) placement, will it be side-by-side, will there be a corner cushion that joins next to other cushions to form an L-Seating area?

Design of the Cushions

What will be the cushion style? Common types are: rollover designs with side bands, rollover designs with corner seams, rollover designs with baseball corners, Side bands in a contrasting stripe placement, Side bands in a solid matching fabric.

If the cushion is a banded cushion, you have three options:

Vertical Stripes

The contrast of a horizontal band to a vertical stripe on the band of the cushion actually can work nicely depending on the stripe.

Screen Shot 2016-06-29 at 2.49.37 PM

Vertical vs. Horizontal Bands

When the face of the back cushion runs vertically, your seat cushion stripes must be patterned so that the stripes match perfectly. A piping accent may be used to enhance the construction transition to a side band in the horizontal or Vertical direction and consistency should be your guide for all cushions.

Screen Shot 2016-06-29 at 2.50.06 PM

Solid Color Band

This can be your best option whether you are just getting started working with stripes, or an experienced fabricator. A solid border and band work nicely when you have a contour corner area to fabricate.

Screen Shot 2016-06-29 at 2.50.20 PM

Above is a combination of a stripe fabric insert with a solid border in a marine vinyl.

It is wise to photograph the area and then sketch or draft examples over the area for consideration to determine the best option for your material direction, project space and a budget when you are estimating time and cost; as project planning, layout and construction time can easily add up when multiple pieces are part of a large layout, as seen below.

Screen Shot 2016-06-29 at 2.50.38 PM

One of my all-time favorites is this Ralph Lauren stripe, juxtaposed for a classic and dramatic impact! Note the stripe placement on the top bands of the corner cushions.

I’m including a few photos of our projects as well as some interesting others that illustrate the variations I’ve explained above. Look around and notice the placement of stripes on cushions and pillows whenever you see them in a residential, commercial or marine project. Trust your instinct, as to what works best or do a mock-up to guarantee a winning combination.Screen Shot 2016-06-29 at 2.50.53 PMThis master cabin bedcover works well with the horizontal stripe on the side banding. The border stripe on the accent pillows unites the patterns for a cohesive look.Screen Shot 2016-06-29 at 2.51.03 PMThese contour cushions are sewn with the stripe as an insert and solid banding and edging on the seat cushions – found on the web – however, notice that the top left back cushion stripes do not match the seat stripe!

Screen Shot 2016-06-29 at 2.51.18 PM

An inviting aft cushion seat, seen at a recent boat show.

In the seating images below I am certain that someone spent a significant amount of time planning and fabricating these striped seat cushions. The side band makes a nice transition on the double seat with a baseball corner. The solid piping provides a clean transition to the stripe in the horizontal direction on the double seat.

Screen Shot 2016-06-29 at 2.51.41 PM

Double Seat – Horizontal Side Band, Baseball Corner, Solid Piping and Rollover Face

Screen Shot 2016-06-29 at 2.51.47 PM

However, I imagine we could all enjoy contemplating the various solutions as to our “best shot” for the corner cushion when a rollover design with this stripe was planned for the multiple seating on this yacht. Send along your thoughts, ideas and any photos you have for a similar project that you may have encountered, I’m interested and welcome your input!

May you enjoy ‘Smooth Sailing’ into Spring!


Leave a comment

Window treatments to WOW your customers

Terri Madden’s January/February 2016 article for Marine Fabricator Magazine.

You can browse the PDF here, or read the text version below.

This article presents  options for the perfect look and fit for those challenging Yacht windows. A bit of experience will help you; yet don’t be daunted by the encounter as just being on this page means that most likely you have already surpassed obstacles for other areas of vessels that were once demanding. Entire lines of blinds and shades are available that can be custom built for any windshield, pilot house, stateroom, galley, or any other window area that you can imagine.

You can take your experience in working with a range of fabrics and combine it beyond your scope for custom window treatments and applications from drop down roman shades to fully motorized systems, nothing is beyond your expertise. The challenge is offering solutions that appeal to your customer’s vision, space and budget. Custom window treatments made with a precise fit, distinctly enhance the value of your customers yacht interior.

There are a large variety of products in a vast assortment of colors and finishes for window treatments. There are several companies that offer services for all your blind and shade needs. No matter if you are doing the patterning, fabrication and installation or using the services of a highly trained manufacturer and installer, you need to make sure that every window treatment and component installed is of marine quality to withstand the harsh conditions of the sea.

Unique Products and Features 

Whether your project is a trapezoid, triangle, or parallelogram etc. it should be accomplished successfully to function reliably and be of exceptional appearance.

The internet is at your fingertips to source ideas, solutions and suppliers. There are numerous boat shows held throughout the U.S. as well as the Fort Lauderdale Boat Show, IBEX and the Miami International Boat Show. These events showcase current trends as well as various sources for manufacturers of window systems.

Exceed expectations with some of the most popular styles:

  • Sheers, Horizontal and Roman Shades
  • Windshield Blinds and Shades
  • Wood Blinds, Aluminum Blinds
  • Hunter Douglas products such as Silhouette, Duette, Pirouette, and Vignette
  • Honeycomb Shades
  • Pleated Shades
  • Hatch Shades and Fly Screens
  • Ocean Sheer

Options to Consider for Installation

Wire Retention System

Yacht blinds should come with a stainless steel wire retention system that prevents blinds and shades from swaying as the vessel moves. The wire itself should be coated in a Teflon clear coat that protects both the cable and blind/shade from being damaged over time.

There are two methods for securing the stainless steel wire. The first method is the deck mount. It is primarily used for inside mount window frame installations. The second method is standoffs. Standoffs are used mainly for an outside mount or out of the ordinary applications.

All wood and aluminum yacht blinds should have the stainless steel wire retention system running through the routing holes and fasten to a standoff. They are mounted directly to the frame to avoid punching extra holes for the wires. On other types of blinds, the wire might have to be placed in a different location.

Standoffs and Hold Downs 

Standoffs can be manufactured from stainless steel, teak, wood dowels, plastic, polished or unpolished aluminum, bronze or plated nickel; that can match any style you are looking for.

Having a stable standoff or hold-down is important for both blinds with either tension or wire retention systems. Standoffs can give clients an easy installation alternative when they want to install their blinds themselves. This way they can save money on installation and still have it look like it was professionally installed.

Motorization

Window Treatments use different brands of motors. Basically all window treatments can be motorized based on your clients’ needs. Motors are available for Silhouettes from Hunter Douglas. Check with an authorized dealer, familiar with a marine installation for  motors such as Somfy or Lutron motors.

Styles to Consider

Blinds and Shades

The Hunter Douglas Silhouettes (a luxury horizontal sheer) has become a popular product within the yachting community and although they are a great product, sometimes there is just not enough room to mount them. However, Poseidon Window Treatments has come up with a solution, Roller Only Ocean Sheer. Most yacht owners know that window depth can limit their selection of viable window treatments. With a roller only application you can mount beautiful blinds with a minimum of 1 7/8″ window depth.Screen Shot 2016-06-29 at 2.30.39 PM.pngAbove: Ocean Sheer – Roller Only

Poseidon has over 20 years of experience manufacturing blinds and shades for the Marine Industry and they are a Hunter Douglas Dealer. Even though I have not had the opportunity to use this company personally, they advertise that their knowledge and experience allows them to adapt their products successfully to any yacht window. They can incorporate various operating systems and other applications into Hunter Douglas products. Their flexibility to fit any blind into any window, with all types of window treatments, provides clients with many options to fit their style and needs.

Writing from experience, I know installation is what really scares most fabricators. Poseidon has streamlined the installation of their blinds and shades so that anyone can install them like a professional. Their easy to mount brackets and wire retention systems are thoroughly tested and proven to be easy to use and install. Along with written instructions they can also walk you through the process on a videophone like Skype, if needed. Their website is Poseidon Window Treatments.

Roman Shades

These have always been my favorite and they have become quite popular on boats and yachts recently. Many owners request them because they give a yacht interior a very soft yet refined look. Shades can be manually operated using a pull cord or they can be easily motorized. You can offer either option to your customer as well as a wide variety of colors, patterns, and fabrics.Screen Shot 2016-06-29 at 2.33.24 PMA Roman Shade from Poseidon

Honeycomb Shades

These are a very flexible product and can fit most windows, doors, windshields and hatches. They give a boat a clean look, are highly durable, easy to use and the cells come in three different sizes of ¾”, 3/8” and 9/16”. They are available in a single, double or triple honeycomb and come in a variety of opacity levels. There are over 50 fabrics and colors to choose from, to match any interior.Screen Shot 2016-06-29 at 2.33.44 PM.pngAbove: Double Cell and Single Cell Honeycomb Shades

Windshield Blinds for Pilot Houses

Every yacht’s pilothouse gets hot during the day; with windshields getting blasted by the sun. Honeycomb shades, 1” wood blinds, aluminum blinds and pleated shades are options that not only keep pilothouses cool, they maximize visibility by using a top down or bottom/up system. Motorization can be added.Screen Shot 2016-06-29 at 2.33.54 PMThe single most effective window treatment for a yacht interior is the covering of the windshield. Photos courtesy of Poseidon Window Treatments.Screen Shot 2016-06-29 at 2.36.24 PMSome Affordable Alternatives for Unique Spaces

CloZures®

Formerly Peek-a-Boo Shutters, these are for irregular or non-opening port lights; when curtains or shades just don’t work. They offer 100% UV protection. Shutters are attached to the glass via 3M a low profile Dual Lock (a Velcro type material). They are easily removed for cleaning. Shutters are available in 3 colors: White, Sea Shell and Chocolate (room darkening). The room-darkening shutter is dark brown on the inside and white on the outside. For samples and more info contact Zarcor Solutions.

Screen Shot 2016-06-29 at 2.36.52 PM

Ocean Air 

The Ocean Air PORTSHADE is an ultra-slim cassette roller blind, suitable for even the smallest port lights. It can be used for vertical or horizontal surfaces, with the added benefit of also being well suited for curved surfaces.

The Ocean Air SKYSCREEN roller surface is a combination fly screen and shade system suitable for boats with no headlining or thin decks. It requires no recess or cavity and can be easily fitted to existing hatches. The soft edged low profile design uses low weight plastic extrusions with integrated screw covers and a simple and reliable magnetic catch system.

The Ocean Air SKYSOL is ideal for curvatures, a day or blackout pleated blind for large sunroofs.

Contact Ocean Air for a dealer near you.Screen Shot 2016-06-29 at 2.37.02 PMAbove: Portshade, Skyscreen and Skysol

Many yacht owners may think that they have windows on their yachts that cannot have proper functioning blinds. As skilled Marine fabricators it is our role to offer solutions for unique shapes of windows as well as windows with a curving radius. These windows may look beautiful yet planning a system that operates reliably and matches the other blinds of the boat can be intimidating.

There is no denying the complexity of fabricating such specialty shaped blinds, but they are far from impossible. Through experience you can develop a system to offer window solutions that function properly and enhance your customers living quarters onboard their yacht…

Much success!


Leave a comment

Salon sofa upgrades

Terri Madden’s June/July 2015 article for Marine Fabricator Magazine.

Browse the PDF here, or read a text version below.

The waters of San Juan, Puerto Rico have been home to many Bertram yacht enthusiasts ever since Richard Bertram opened a 25-acre plant in 1962. I have had the good fortune to hone my skills and deliver full interior projects for several of the various models.

From the moment one steps aboard one of these classic vessels there is an appreciation as to why the Bertram 50 convertible which debuted in 1986 was dubbed ‘the slickest Bertram yet’ by Boating magazine.

The Caribbean is well known for tournament fishing and in 1995 Bertram introduced the Moppie 46, which was capable of speeds faster than 37 knots. It was well suited for fishing tournaments and cruising down-island. Simultaneously the 54’ convertible interior was redesigned whereas the classic hull was left intact “because you don’t change perfection.”*

It is no wonder that after a history of 50 years these vessels have a predominate presence on tropical waters and now a second generation of owners retrofits these vessels and our expertise is called upon to refurbish and improve upon the original seating for the safety and stability of the owners, regardless of the location or conditions out on the ocean. In this article I will detail the decisions, design changes and conclusions for fresh new looks on a sofa of a 2001 Bertram 51’ and a 1996 Bertram 50′.

My first impression from the moment I step aboard a 50’ boat doesn’t have to be my lasting impression. I delight in planning and fabricating a functional and contemporary style that maintains the integrity of the classic lines of a vessel. Collaborating with customers is sometimes like a Tango, yet it is an essential component whereby the final outcome reflects the taste of the owner. There has been an explosion of suitable marine materials in fabric, vinyl or leather that fabricators can provide for a basic as well as dramatic effect in the marine environment

Especially for the creative minds of marine fabricators…the sofa is generally the most frequently used piece of furniture on a boat and the materials particular to the class of vessel like a Bertram command an elegant statement yet they must withstand company and crew who may even ‘live aboard’ the boat. Captains generally have to provision the boat and store items under sofa cushions for get-a-ways and fishing excursions. These areas must be easily accessible yet the exterior material takes the brunt of everything from fishing poles, grocery boxes to refreshments. Yet in less than a few hours it must make a Cinderella transformation for owners and guests.

You may be contacted for a retrofit on a vessel as soon as the owner takes charge of his new boat; sometimes they don’t like the manufacturers design or the boat had been a display model. In this case the “Style” may still look current and just a change of material will suffice.

I have generally been contacted to re-do the interiors when a boat changes owners and the boat is 5-15 years old. Materials may be worn and the style look “dated”. Generally the sofa on a 50’ boat is an L-shaped design to provide maximum seating in a tight space. Currently some vessels have a rectangle sofa on each the port and starboard side. In this case your work may be less as smaller sofas can be easily transported to your shop and side-by-side alignment isn’t necessary.

This is your opportunity to improve upon the design, especially if the frame is good.

Tips:

  • Check the alignment of side-by-side pieces. It is crucial, as we almost missed making a 1” height adjustment on the factory model of the Bertram 51’.
  • Start with pictures of the sofa at every angle.
  • Measure twice for ordering materials.
  • Keep in mind the additional time required if you are removing the original material outside and inside storage areas.
  • Seat foam generally should be replaced, yet back foam may be ok to reuse with a Dacron topper.
  • Trends – visit boat shows to see the 2015-2016 designs.

Considerations:

  • Will you make design adjustments?
  • Style adjustments: Contemporary or Traditional?
  • Will you modify the existing frame, design/location/type of modifications?
  • Is the overall ‘look’ sleek, pleated or oversized?
  • Are corners pleated to save time or seams fabricated with accent topstitching?
  • What will be the cushion style: rollover fronts, banded sides, matching or contrast piping?
  • Are sofa corners with or without arms?
  • Are the seat & back cushions designed with a flat surface, or a Hi-Lo combination of foam and contours?
  • Will Memory foam toppers add comfort to the arms?
  • Surface Materials: Fabric, Vinyl or Leather?
  • Thread:  Contrast Accent of matching color – Thread size?
  • Material combinations and types of materials: pattern alignment: stripe, plaid, geometric, combinations of quilted and solid sections increase the level of difficulty.

Bertram 51’ 2001

This boat was frequently used for fishing and entertaining and the customer contacted Sand Sea and Air to replace the leather in an Ultra Leather (vinyl), as part of a complete refurbishing project.

Upon inspection it seemed odd that the sofa side arms were unusually high as well as narrow for the proportion of the sofa. The owner liked our idea to: widening the arms, lower the arms by approximately 6” and insert a memory foam topper for comfort across the top of the arms. New high-density seat foam replaced the worn out seat foam; deterioration was due to the frequent use and travel by the owner to nearby islands.  All of the seat cushions were reversible and the foam was Dacron wrapped for a plush look with a refined style.

The new contour on the arm was noted at the boat and the section was cut off from the top of the original arm frame after the original material was removed. Sampling and patterning was needed to position the material on the sofa back where it had to be “filled-in” and extended to meet the top of the new ‘lower’ arm.

Bertram 51’ Sofa: Before / In-Process PhotosScreen Shot 2016-06-29 at 12.07.28 PM.pngAttention to the final height of adjoining sections is extremely important and placing the side-by-side frames next to one another during assembly is highly recommended. As it would be very time consuming to correct adjustments on the boat once the back of the sofa is stapled and closed.

Our client was extremely pleased with the design and the comfort on the refurbished sofa sections.

See: After PhotosScreen Shot 2016-06-29 at 12.08.20 PM.png

Bertram 50’ 1996

This client grew up on a Bertram 50’ and he had fond memories of his time spent aboard. His recent purchase of a 16 year old yacht had a navy sofa that looked “old-fashioned” and he and his sophisticated wife were delighted to know that ‘the bones” of the L-shaped sofa were good and that our reputation proceeded us to transform his boat. The pillow backs that attached to the back and the arms of the frame were removed and we scheduled mock-up visits for the new design and material selections.

A rollover design was selected for the individual seat and back cushions to soften the overall appearance; whereas cushions with side bands would have looked ‘too boxy’ with the rectangle lines of the frame.

We put an extra layer of foam on the back frame and fabricated individual higher ‘pillow-back style’ cushions for more comfortable sofa seating.

Bertram 50’ Sofa: Before                                                      Sofa: Mock UpScreen Shot 2016-06-29 at 12.09.15 PMThe sloped frame on the arms was reshaped to a squared edge to match the sofa frame.

The navy leather on the original frame was replaced with beautiful and durable Sunbrella “Salt” Sailcloth that coordinated perfectly with the ”Taupe”, “Cinnamon” and “Ivory” materials on the ottomans, coffee table and dinette.

Bertram 50’ Sofa: In-processScreen Shot 2016-06-29 at 12.10.47 PMThe final dramatic sofa lines were in balance and harmony with the classic foundation of a Bertram.

You can achieve this goal on every sofa project also; no matter what the size, make or model; experience helps, do your research and trust your instinct!

Bertram 50’ Sofa: After Screen Shot 2016-06-29 at 12.11.56 PM.png

*www.Bertram.com/timeline/