Boston Whaler Construction | Boston Whaler Military
Boston Whaler Construction

Boston Whaler | Construction

Boston Whaler was thrust into the national limelight in 1961 when Life magazine pictured founder Richard T. Fisher as he sawed a 13-footer in half and drove off in the half with the engine. Thanks to Whaler's unique Unibond construction, you can still do that today. And nowhere is that more valuable than in commercial and governmental applications.
In more common scenarios, commercial Whalers are subject to repeated intentional groundings, punctures by submerged objects, and even impact from collisions in dense fog. There are literally hundreds of stories where Whalers have remained afloat with significant damage- a 3' hole in the bottom, the bow crushed, etc. - and returned their crew safely to shore.
This remarkable Unibond construction provides up to 2-1/2 times the flotation required by the US Coast Guard. Here's how it works.

Unlike most molds, the Whaler hull mold is comprised of two pieces. Each is coated with gelcoat and a skin coat of fiberglass before multiple layers of bi- and tri-directional fiberglass material is applied. The two molds are then latched together and a precise amount of liquid closed-cell foam is poured into the area between the hull molds.

The foam expands and fills the space between the molds permanently bonding the halves into a single, inseparable unit. This results in an extremely strong and unsinkable hull. Pound your fist on the side of a Whaler versus another boat and you'll see what we mean.
Little details make a big difference, especially in a tough commercial or military environment. All Whalers use 316-L stainless steel deck hardware (much tougher than the 304 stainless steel in most marine applications), and we even take an extra step to chrome-plate our screws for additional corrosion resistance. The nonskid pattern is molded right into the deck, not added later. The electrical wiring consists of tinned copper, not bare copper, and the wiring connectors are heat shrunk, not just clamped, to virtually eliminate the possibility of moisture entering the wire core.

T-tops, seating, gun mounts, tow posts, and cleats are backed by Whaleboard, or aluminum, which are impervious to rot from water intrusion and have a screw retention 5 times the strength of wood.
Whalers aren't technically bulletproof; but they definitely give you one less thing to worry about. Learn more about the available options on BCGP boats.