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Factory Tour...

This section of the Jones Brothers website follows a Cape Fisherman through the manufacturing process. After a short description of each manufacturing area in the plant, use the image gallery at the bottom of the page to watch the construction of a boat.
   

Woodshop

The "woodshop" is a holdover from the good old days - no wood is used on any of the boats currently manufactured by Jones Brothers. Nowdays, the woodshop cuts the foam and other composite pieces that will be used by Lamination and Small Parts.
   

Lamination

Lamination builds the hull, stringers, and floor. The major components of the boat are assembled in Lamination, and then passed to Finishing for final assembly.

   

Small Parts

The Small Parts group builds the console, deck cap, hatches, and any necessary livewell, jump seats, and/or leaning posts for a boat. Most of the fiberglass parts used by Jones Brothers are built in-house to insure the quality and consistency of the finished product.
   

Finishing

Early in the manufacturing process, Finishing examines the order for the engine(s) and options used on the boat. Inventory is set aside for final assembly.

When Finishing gets the boat from Lamination, and the remaining components from Small Parts, each piece gets inspected and the imperfections are fixed. Once all the parts have the proper fit and finish, the boat continues down the assembly line and the boat finally comes together.
   

Use the following image gallery to follow a boat through production:

  • Cutting fiberglass material on the cutting table
    Lamination cuts patterns from rolls of fiberglass material. Using patterns insures consistent weight and strength when they are interlocked during the construction process.
  • Woodshop cuts the foam and composite pieces used in the boat
    While Lamination is cutting material, the woodshop cuts the foam and other composite pieces that will be used by Lamination and Small Parts.
  • Applying the gel coat into a mold
    After prepping the molds, the gel coat is applied to the hull mold.
  • Handlaying fiberglass into the hull mold
    After the gel coat sets, the fiberglass patterns are handlaid, and all air bubbles are "picked" from the fiberglass and resin layers for strength and longevity. Also, the lamination layers are applied using a "schedule" to insure consistent thickness and weight.
  • Installing the transom
    The transom is now constructed using a special high-density foam core. The process insures a perfect bond between the hull lamination layer and the new transom.
  • A cross section of the Transom
    The transom uses a foam core with special properties. It's very heavy, dense, extremely difficult to compress and is absolutely waterproof. The finished transom has approximately 1/2 an inch of laminate on each side of the foam core.
  • Building the stringer grid
    At the same time the hull is being constructed, the lamination crew builds the fiberglass stringer grid. While this part is not as attractive in a finished sense, it's very important that the fiberglass patterns used on the stringer grid are interlocked during the build process for maximum strength. Sheets of recycled ABS plastic are strategically placed inside the stringer grid. The ABS composite material holds screws extremely well and will be used to anchor the console, and optional seats or leaning post live wells.
  • Pulling the stringer grid from the mold
    There is a LOT of glass used in the stringer grid. Hoists are being used to pull the stringer from the mold.
  • Adding glue to the stringer grid
    The stringer grid is now finished, and the crew is adding the glue to the bottom of the grid.
  • Glassing in the stringer grid
    After the stringer grid has set, additional glass is added to insure a solid bond with the hull.
  • Hull with stringer grid tank and foam installed
    The tank has now been installed and foamed in-place. Foam also gets injected inside the grid and into the cavities under the floor. The black parts are ABS composite sheets built into the stringer grid which are used to anchor the console, and optional seats or leaning post live wells.
  • Building the floor on the vacuum table
    The Lamination crew also creates a composite floor on a vacuum table.
  • A cross section of the floor
    The foam core used by the floor looks somewhat like the foam "noodles" used by kids at a swimming pool - it's extremely light, thin and flexible. The foam sheets have very small holes that penetrate the material. When the lamination layers are applied with a vacuum bag, the resin fills the holes to create support columns inside the foam. When finished, the one piece floor is extremely stiff and strong, and able to withstand the impact of a dropped anchor.
  • Apply glue for the floor
    After installing the fuel tank and filling the floor cavities with foam, the floor is glued on top of the stringer grid.
  • Install the floor
    Note the lack of deflection in the floor being installed in this photo. The flexible foam core with the lamination installed is now a very solid structure that can easily support a full-size adult standing in the middle of a suspended floor. Once installed on top of the stringer grid, the floor is super solid.
  • Gluing and glassing the floor to the hull
    After the floor has been glued to the stringer grid, the floor is also glued and glassed to the hull.
  • Painting the cockpit
    The cockpit has been ground and sanded smooth, and is now being painted. The non-skid surface is applied during this last step in Lamination.
  • The painted hull ready to come out of lamination
    Lamination is now finished with the the basic hull, and it's ready to move to Finishing.
  • A console and deck cap being built by Small Parts
    While Lamination has been constructing the basic boat, Small Parts builds the console, deck cap and other options used to finish the boat. Note the foam core used in the deck cap mold on the right. The core creates parts that are very strong and rigid.
  • The deck cap being installed
    The boat is finally coming together. After installing the deck cap, the finishing crew will add the console, leaning post and hatches.
  • Adding the rub rail
    Hardcrab, one of the finishing crew, installs the rub rail on the Cape Fisherman.
  • Assembling the console
    Randy gets started assembling the console for the new boat. The console is the nerve center for all Jones Brothers boats. The wiring, switches, cables, and batteries are easily accessible.
  • Buffing the Hull
    The hull and all the components built by Small Parts are inspected. Any imperfections are repaired, and all the surfaces are polished.
  • Installing the Console
    The console is up on-end, and adhesive is being added to the bottom. After carefully aligning the console, it will be flipped down and anchored into the ABS composite that was built into the stringer grid.
  • Installing the Engine
    A hoist is being used to install the Yamaha four-stroke on the transom.
  • Adding the Decal
    Kristen adds the Jones Brothers decal. She also details the boat, and goes through a checklist to insure that all components are installed, and the cushions, plugs, accessories are on-board before shipping.
  • Almost out the door
    The boat is ready to leave the factory, and will be soon be loaded onto a truck for transport to a dealership.
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