Construction

Carolina Cats are built for speed, soft ride and stability with unique planing hull designs that skim the top surface of the water with minimal power, wave-parting dry ride and silky-soft re-entry. The process begins with 3D computer design models, full sized mock-ups and weighted hull testing to maximize performance.

Carolina Cats are all-composite construction with fiberglass stringer systems and high-density composite transoms and coring to give each boat lasting strength and stiffness. These high-technology materials are more expensive than wood-based reinforcements, but will never be subject to rot.

The boat building process begins with the tough, flexible exterior gel coat Then, three ounces of hand-rolled skin coat is applied, giving the Carolina Cat a water-resistant skin coat barrier. The skin coat is followed by multiple layers of biaxial knitted fiberglass cloth, overlapped in water shock areas then rolled smooth by hand for a higher glass to resin ratio than traditional woven roving laminates.

Fiberglass stringer grid systems are injected with 2 pound closed-cell foam for basic flotation, strength and sound absorption.

Fiberglass grid stringer systems are nested into the hull utilizing steel production fixtures for precise placement and stringer height. Then, the stringer system is bonded to the hull interiors with a combination of knitted fiberglass cloth and methacrylate for both chemical and fiberglass bonds imparting maximum strength and durability. The methacrylate alone has a tensile (pull-apart) strength of 4000 pounds per square inch.

After the Carolina Cat stringer system is fitted into the hulls, the tops of the stringers are securely bonded to the deck with more fiberglass and methacrylate for a unitized hull/ stringer/ deck construction architecture. This dedication to structural integrity is important; a Carolina Cat can safely and comfortably navigate rougher seas at higher speeds than conventional monohull designs and requires the superior strength produced by this unibody construction design.

Deck hardware is fabricated of marine grade stainless steel and bow rails are heavy brushed aluminum or stainless steel for low maintenance durability in harsh salt water environments. Hardware subject to stress, like rod holders, hand holds, bow rails and cleats are backed and securely through bolted with aircraft-type locking nuts.

Carolina Cats utilize polyethylene fuel cells that are impervious both to corrosion from salt water and deterioration from ethanol fuels. Fuel cells are installed under the console in the 18CC and under the decks in larger Carolina Cats.

Premium 32-mil marine-grade vinyl and open cell foam are used on all upholstery for maximum tear and mildew resistance.

Hull to deck joints at the gunwales are bonded with a combination of epoxy tipped stainless steel screws, fiberglass putty and marine adhesive for a watertight chemical and mechanical bond. Then the heavy-duty gunwale molding is installed with more stainless screws around the deck ring, followed by a stainless sheer metal insert for incredible stiffness and strength.

Electrical systems, harnesses and gauges are tested in the factory. Batteries are installed and tested. And, when ordered factory rigged, the Yamaha four-stroke engines are readied and fired before the boat ships to a Carolina Cat dealership. So, when a Carolina Cat leaves the factory, we know that it is ready to take your family for great adventures on the water.