Full Enclosure & Sunpad

Sea Ray 500 Custom Full Enclosure FWD View (Makrolon Windows)For this Sea Ray 500, the bridge was constricting the captain, so we raised the framing 6 inches for more headroom.

We also made a new aft frame for this boat so that the customers could have more shade with  their new enclosure. We brought the pole out further towards the back of the boat, so that the bimini could be wider then their last cover.

After we did some adjustments on their framing, we went and took measurements with our 3d measuring device. Then our designer went back to the shop and  started working his magic designing a custom enclosure.

Sea Ray 500 Custom Full Enclosure AFT View (Strataglass Roll Ups)

For this project we used Sunbrella fabric in Captains Navy, GORE tenara thread in black, Lenzip zippers. Both GORE tenara thread and Lenzip zippers have a lifetime warranty. That means they are guaranteed to last longer then your canvas and that the sun and water will not eat away at them!

For the forward windows we used Makrolon, which is made out of a polycarbanate that makes these windows semi-rigid! For the aft windows we used Strataglass. We did roll ups for some of the back windows for air flow when the cover is up. To ensure no water leakage in the roll up windows we used Lenzip’s waterproof chain zipper. 

Sea Ray 500 Custom Sunpad

We also designed and sewed up four separate custom sunpads for this boat. We used Captains Navy Sunbrella upholstery fabric to match the new closure we created for them! These cushions have an Oyster Sunbrella piping around the edges to help create the illusion that these are all one long cushion! They also have two easily removable headrests that have pockets in the back of them for storage so that things don’t go flying away when you are out and about. They are attached to the boat with custom velcro straps that wrap around poles located down each side of the center of the boat. These cushions aren’t going anywhere but where the boat takes them!

Sea Ray 500 Custom Sunpad Detail Of Head Rest

They are made out of active foams dryfast foam. Dryfast foam is an open-cell foam that allows water to go through the foam instead of absorbing it like other foams. These cushions will get dry way quicker if they get wet out on the water or soaked after a rain storm. They also have a white screen on their underside to also help with water drainage along with a large horse shoe shaped zipper for easy removal if the customer wants to throw these in the wash at the end of the year.

Roll Up Window Replacements

A customer came to us with  a roll up window replacement because their windows were yellowing. This can happen over the years, from sun and weather, or even from boat cleaner chemicals getting on the glass.
To replace these windows we used strataglass, sunbrella binding, and lenzip’s waterproof chain zipper.

Our process to do this is to first take measurements of the windows using our 3D measuring device while the old glass is inside the windows still. We could do it this way because the customer said the windows still fit perfectly, they weren’t too big or small when he put them on his boat recently.

After we take the measurements we do the design work on the computer using CAD software. Then we draw out the new windows using our plotting device so they are exactly what we need.

Then we cut out the old windows, removing all the old discolored glass. After that we put down seamstick which is a double sided tape that helps keep all of our sewing holes a little more waterproof. Over time, dirt and outside debris will get in there and stick to the tape, creating a blockage in the needle hole. We put this all along the outside edge of the glass.

Then we put that aside, and we do the roll up window. First we put down the water proof zipper, also using seamstick. After the zipper is down, we put binding we’ve sew up on the front and back of the window, so it looks nice and clean. After that, we sew down the zipper, then we place the new window into the old canvas, and sew it down.