sail-world.com
 
 
News Home Cruising Photo Gallery Video Gallery

 

Sail-World.com : America's Cup: First images of the AC45 construction at Warkworth

America's Cup: First images of the AC45 construction at Warkworth

'AC45 male mould under construction - BMW Oracle Racing building facility - Warkworth'    © Richard Gladwell    Click Here to view large photo

BMW Oracle Racing look to be set to put the sleepy northern Auckland town of Warkworth on the technology map with the establishment of a new hi-tech boatbuilding facility that will employ between 50-70 people.

The new facility to be known as Core Composites is off to a flying start with the production of the new America's Cup 45 class of catamaran, but will be also supplying to other boat builders and users of composite components.

Based in the old Rodney and Waitemata Times production facility, previously a major employer in the area, the building has plenty of open floor area and high ceilings – ideal for some of the big gear either already installed or on order.

Already one five axis machining centre is installed - which will handle a component of 6metres x 3 metres by 1.5 metres. Kerry Jones, who is in charge of the machining at Core Composites describes it as 'the Baby'. But it is the biggest machine of its type in New Zealand.

One of the ovens in the very ample BMW Oracle Racing building facility - Warkworth -  © Richard Gladwell?nid=74716   Click Here to view large photo

A second 'Monster'machining centre will take components up to 26 metres in length.

'We have these two five axis CNC machining centers, a CNC lathe and some other equipment basically to handle the capacity that we have rather than outsourcing all the parts that we do for the rigging', explains Jones.

'We probably will outsource some specialised components – when it comes to America’s Cup boats we will have to do the hulls in America. That is in the Protocol', explains Chief Operating Officer, Stephen Barclay.

The grand scheme is to be able to build all components for the AC45 class on site and thanks to some liberal rules in the new Protocol for the 34th America’s Cup, only the hulls of the BMW Oracle Racing’s AC72 yachts need be constructed in the USA. A special team will be sent from New Zealand to USA to do this.

The AC72 wingsail, foils and all other components can be manufactured in the Warkworth facility.

The five head 'baby' machining centre in the BMW Oracle Racing building facility - Warkworth. Capable of taking material up to 6 metres in length (the largest machine of its type in NZ) a second machine capable of handling 26 metres is on its way. -  © Richard Gladwell?nid=74716   Click Here to view large photo

'We have the capability to do everything,' adds Jones, turning to the big five axis machining centre, which he refers to as 'the Baby'.

'This is the smaller one of the two that we have', explains Jones. 'It has a tilting rotary head so we have full five axis of movement on the head and a 6-meter stroke by 3-meter by 1.5 meter on the Z axis. '

Think of three dimensional drawings with width depth and height ('X', 'Y' and 'Z' dimensions) and you have an idea of the composite engineering art forms these machines can produce.

'It is the only one of its kind in New Zealand at the moment,' says Jones. 'We are getting a bigger one which is going in what we call the boat shed (really a huge two or three level room the size of a warehouse).

'This one will fit on the table of the big one', explains Jones to underline the size of the new beast.

The 'room' where the big machine centre will be based - BMW Oracle Racing building facility - Warkworth -  © Richard Gladwell?nid=74716   Click Here to view large photo

'It is designed for the aerospace industry, and making spar component parts, it is quite widely used by Boeing and companies like that. It can machine up turbine blades, and not just marine stuff, but also automotive and aerospace components,' he adds.

'The machine are going to be used for doing a lot of the mould work for the composite construction', explains Barclay. 'We get the designs from the design crew and then we convert that into cutting files and then we basically supply all the mould components to the boat builders.

'In the past we would have to an outside company to get tooling and components made. That cost a fortune and you are beholden to the outside companies in terms of timing and things like that.

A larger oven at the BMW Oracle Racing building facility - Warkworth. Even so, this is one of the smaller ones planned. -  © Richard Gladwell?nid=74716   Click Here to view large photo

'By having these machines in-house we can do all of that stuff ourselves. Of course over time we can amortise the cost of it, so if we have a long-term use it will actually be cheaper for us to be able to handle this capability in-house. '

As mentioned 'the Baby' can handle components measuring 6-meter by 3-meter by 1.5 meter.

And the big one?

'The big machine is going to be 26-meter long by 6-meter by 3.5 metres' says Jones, drooling ever so slightly.

Barclay explains that 'the Beast' is going to be hitting a roof in the boat shed. 'It will be 9-meter high. It is a massive machine that can basically machine a whole boat - the whole hull. It will take up most of this shed - with a sail-loft at the other end.'

Another machining room - BMW Oracle Racing building facility - Warkworth -  © Richard Gladwell?nid=74716   Click Here to view large photo


BMW Oracle Racing purchased the facility about 18 months ago

'The ambition and reason why we did it was that the team has aspirations of being around for a long time . We spent so much money to finish products around the world so that is really the reason for doing it, it actually saves us money. And of course, we can guarantee the quality which for any big team is really important,' explains Barclay.

About 50-70 boat builders will be employed at Core Composites, the reason for the shift to New Zealand is that the labour costs are less and the skills and engineering expertise are high. 'We are looking at working with a lot of New Zealand’s resource to help us with the AC 45 project and we are actively talking to a number of contracting companies at the moment', says Barclay.

Another plus for the Warkworth facility is that it allows the storage of an enormous amount of kit. 'When you have been an America’s Cup Team in operation since 1990, you acquire a lot of gear', explains Barclay resignedly. 'It will be good to see what we really have in the one place.'

AC45 male mould under construction - BMW Oracle Racing building facility - Warkworth -  © Richard Gladwell?nid=74716   Click Here to view large photo

Construction is well advanced with the male moulds for the AC 45 class of which six are expected to be sailing by mid-2011. The first will be launched in January 2011. Each competing team in the 34th America's Cup will own at least one of the yachts, maybe two. The wingsails for the AC45's will also be built in Warkworth on the same floor.

Right now the focus of Core Composites is to get the AC45’s into production.

'It will be America’s Cup Race Management and the yet to be appointed Regatta Director’s responsibility to determine who gets their boats first, and overseeing the training program we are looking to put in place before Christmas,' says Barclay.

AC45 male mould under construction - BMW Oracle Racing building facility - Warkworth -  © Richard Gladwell?nid=74716   Click Here to view large photo

'The idea is that all the teams can come down and learn about these, and learn about sailing the boats and learn about the logistics of the wing – all that sort of stuff.

'It is the Regatta director’s job to make sure that all the teams are handled in a way that is fair and equitable.'

'We are certainly up and running.'

Male moulds and oven - BMW Oracle Racing building facility - Warkworth -  © Richard Gladwell?nid=74716   Click Here to view large photo




by Richard Gladwell

  

Click on the FB Like link to post this story to your FB wall

http://www.sail-world.com/index.cfm?nid=74716

1:18 AM Thu 16 Sep 2010 GMT






Click here for printer friendly version
Click here to send us feedback or comments about this story.

Click for further information on
2013 America's Cup

Related News Stories:

20 Dec 2014  America's Cup: Full CAS report finds both ISAF and de Ridder at fault
20 Dec 2014  America's Cup: Lawsuit against Oracle Racing lodged in San Francisco
19 Dec 2014  America's Cup: Full CAS report finds both ISAF and de Ridder at fault
12 Dec 2014  America's Cup: Oracle crew member's penalty for cheating is reduced
29 Sep 2014  America's Cup: Oracle Team USA's AC72 takes to the streets
27 Sep 2014  America's Cup: Then and now - Coutts on why Oracle won, and the Venue
09 Aug 2014  America's Cup: Former Artemis crew member says danger is being ignored
27 May 2014  America's Cup: Oracle Team USA under stress
23 May 2014  America's Cup: Oracle and Team NZ designers reveal AC72 secrets
22 May 2014  America's Cup: Artemis death verdict 'result of an human act'
MORE STORIES ...

News - USA and the World

Sail-World is now running live in the changed website format. If you are running on a Mac with iOS please scroll to the bottom of the site and check that your region is set for your region and not some other. It can be correctly set up using the drop down boxes. Then go to the top, click refresh, and you should be away. ... [more]  

Rolex Sydney Hobart: Wild Oats XI and Comanche Finish Images *Feature by Crosbie Lorimer, Hobart, Tasmania
The Comanche and Wild Oats XI teams were equally gracious in victory and defeat on the dockside in Hobart today. It had been a close fought battle and while Comanche had reeled Wild Oats XI back in overnight to within 9nm , there simply wasn't enough air to power up the American boat in the run across Storm Bay and up the Derwent River. ... [more]  

Rolex Sydney Hobart Yacht Race 2014: In what skipper Mark Richards described as the crew’s most hard-fought line honours triumph, Wild Oats XI held off the impressive challenge posed by Comanche, the newly-launched entry from the United States. Completing the race in 2 days, 2 hours, 3 minutes and 26 seconds, Wild Oats XI finished eight hours shy of the race record she set in 2012. ... [more]  

After being dismasted a short time ago in the Rolex Sydney Hobart, Giacomo is motoring to the lee of Maria Island. In other race news, a very disappointed Bill Wild has retired his Reichel/Pugh 55, Wedgetail, from the race after suffering mast damage in the Cruising Yacht Club of Australia’s 628 nautical mile race at approximately 7.40pm off Schouten Island. All are safe and well on board. ... [more]  

Rolex Sydney Hobart Yacht Race 2014: Spithill was one of six helmsmen on Comanche. 'We can’t leave it at that,' he declared after finishing in Hobart. He says that on his watch this morning the boat reached a top speed of 32 knots and knows what she is capable of. 'Everybody got to see the true potential of this boat at the start. ... [more]  

Top international yachting photographer, Carlo Borlenghi was in the air above the Rolex Sydney Hobart Race fleet and provided these images of the third day of racing in the classic ocean race, as the leaders closed in on the finish, and the dock celebrations by Wild Oats XI. ... [more]  

Rolex Sydney Hobart Yacht Race - 'This is the sweetest victory by far,' Wild Oats XI skipper Mark Richards declared today after steering the silver-grey thoroughbred to a record eighth line honours victory in the Rolex Sydney Hobart. 'To rewrite a bit of sailing history doesn’t come along every day. To win a Hobart is a great honour but to win an eighth; I can’t believe I am here,' Richards said. ... [more]  

Photographer Andrea Francolini was on the water at 2014 Rolex Sydney Hobart Yacht Race line honours finish and provided this gallery of images. ... [more]  

Wild Oats XI entered the Derwent River some forty minutes ahead of Comanche at the Iron Pot and gybed her way up river in 5-10 knot southeaster, bright sunshine and crystal clear light to take a record breaking eighth line honours win in this race at 3.03pm The size of spectator fleet that accompanied Wild Oats XI and the crowds on the dock were much the largest ever sen for this race. ... [more]  

The Volvo 70 Giacomo has lost her rig in the vicinity of Maria Island. A second yacht Wedgetail (an RP55) lost the top off her mast in the same area at the same time. Giacomo is a Volvo 70 owned and skippered by Jim Delegat (NZL) and has a full New Zealand crew aboard ... [more]  

Rolex Sydney Hobart Wild Oats XI takes number eight by Rob Kothe and the Sail-World Team
Wild Oats XI finished at 303pm, with her big A2 flying. Her elapsed time was two days two hours three minutes and twenty six seconds 02:02:03:26 That was some eight hours outside the race record she set in 2012 of 1 day, 18 hours, 23 minutes and 12 seconds. ... [more]  

At the 2014 Rolex Sydney Hobart Yacht Race photographer Daniel Forster was on the water and provided this gallery of images from Day 2. ... [more]  

Rolex Sydney Hobart: Wild Oats XI scores comfortable 8th win by Richard Gladwell, Sail-World.com/nz
Wild Oats XI (Oatley family) has crossed the finish line for the Rolex Sydney Hobart race to take her eighth win in the offshore classic. She crossed the finish line in the Derwent River sailing on port tack with a big asymmetrical headsail flying, and accompanied by a bevy of spectator craft as she crossed the finish line at 3.00pm local time. ... [more]  

In Alamitos Bay Yacht Club's annual Boxing Day race the hometown Gibbs brothers, Riley, 18, and Sawyer, 16, started last in their 49er skiff but passed all of the other boats of various types to finish first in brilliant sun but cool light air Sunday. ... [more]  

2014 Rolex Sydney Hobart Yacht Race - Wild Oats XI is still leading the 2014 Rolex Sydney Hobart, some 38-nm from Hobart, and hoping to close in on a record eighth line honours win. ... [more]  

2014 Rolex Sydney Hobart Yacht Race - The crew on the American super maxi Comanche have not thrown in the towel. They do not believe the race for line honours in the Rolex Sydney Hobart is over despite Wild Oats XI’s commanding lead. ... [more]  

2014 Rolex Sydney Hobart Yacht Race - Bob Oatley’s 10 year-old super maxi Wild Oats XI is racing towards an historic eighth line honours victory in the Rolex Sydney Hobart this morning. ... [more]  

Rolex Sydney Hobart: Wild Oats rounds Tasman Island by Richard Gladwell, Sail-World.com/nz
Seven time race winner, Wild Oats XI (Oatley family) looks set to take her eighth win, after rounding Tasman Island just before noon, local time. The supermaxi rounded the landmark with a ten mile lead over the US supermaxi Comanche and has about 35nm to sail in a direct line to the finish line off Hobart. ... [more]  

With the front runners in the Rolex Sydney Hobart expected to sneak through in light to moderate tail winds, the weather prognosis for the remainder of the fleet is, well, interesting. The simple analysis is that fresh northerly winds will give the fleet a fast ride on Sunday and during the daylight hours of Monday. ... [more]  

Wild Oats XI (Oatley family) is expected to cross the finish line, around 4pm on Sunday and take her eighth line honours win. The race leaders are making good time down the coast of Tasmania, and at daybreak had approximately 100nm to sail. ... [more]  

Sydney to Hobart - Another 40 foot white-wash? by Rob Kothe and the Sail-World team
With the Supermaxi battle probably all over in this 70th Rolex Sydney to Hobart race, unless Wild Oats XI drops her rig in the next five hours, she is set to take her eighth line honours victory so at last the attention will shift to the real race, the battle for handicap honours. ... [more]  

Rolex Sydney Hobart: Your Turn, Then My Turn, Then Your Turn! *Feature by Crosbie Lorimer, Hobart, Tasmania
With the front runners over halfway to Hobart, this year’s race is turning out to be quite a page turner already; and that’s just the big boats. So let’s start with them. Wind back to the start, first honours to Comanche in the shoot out to the first mark. To be fair it was akin to pitting a brand new Bugatti Veyron against some classy and quick Ferraris and Porsches. The result in those ... [more]  

There is absolutely no way anyone can predict these before the vast majority of the still 109 vessels racing actually get home to Hobart Town. One can, however, talk about the very things that do go into making these results that so many chase and to do so, we have to work through a myriad of vessel designs, ages and types. ... [more]  

Rolex Sydney Hobart 2014; Handicap Honours Predictions VIDEO *Feature by Dale Lorimer, Hobart, Tasmania
Given the weather models for the race, Crosbie Lorimer did the rounds of the CYCA dock just prior to the start of the race to find out who the various skippers, navigators and tacticians believed might take out the overall Handicap win on IRC. Here are some of their predictions, how they are panning out for some and an update on the position at the front of the fleet. ... [more]  

Sydney Hobart 2014: A ridge too far for Comanche by Bruce Montgomery, RSHYR Media
2014 Rolex Sydney Hobart Yacht Race - That’s the conclusion that one might well draw from the huge difference in the performance of the Hamilton Island super maxi Wild Oats XI and her main challenger, the US boat Comanche. ... [more]  

Photographer Daniel Forster was in the air again for the Sydney Hobart 2014, and provided this gallery of images. ... [more]  

2014 Rolex Sydney Hobart Yacht Race - The chase for line honours at the 2014 Rolex Sydney Hobart Yacht Race is intensifying with the leading boats approaching the halfway mark of the 628-nm race. ... [more]  

By Grand Prix ocean racing standards she’s an old girl, and there’s no denying she’s had a few makeovers during the past decade, but Bob Oatley’s 30-metre long supermaxi, Wild Oats XI, was leaving no doubt today that when it came to speed she’s still got great legs. ... [more]  

2014 Rolex Sydney Hobart Yacht Race - After 24 hours the Hamilton Island supermaxi Wild Oats XI has taken the lead for the first time in the Rolex Sydney Hobart Yacht Race, the 70th sailing of the event. ... [more]  

Photographer Howard Wright was on the water at the start of the 2014 Rolex Sydney Hobart Yacht Race, and provided this gallery of images. ... [more]  

Looking back it is not so long ago that sailors making long trips had to make the key choice between light weight and taste. But now, thankfully, technology and demand means that there is more and better choice in freeze dried foods. But the lack of fresh food and the limited choice of diet does mean eating remains a chore, part of the daily routine during the three months ... [more]  

2015 Fireball World Championship - The event offers two weeks of unrivalled sailing in the beautiful waters of North Wales. Situated on the Llyn peninsular, just 10 miles from the Snowdonia National Park, racing will take place in Cardigan Bay within easy reach of the sandy beach from where the fleet will launch. ... [more]  

Rolex Sydney Hobart: Supermaxi Race Start VIDEO *Feature by Dale Lorimer, Sydney
The start of the Sydney to Hobart Yacht Race saw the five 100 foot super maxis up against each other for the first time. ... [more]  

Rolex Sydney Hobart: Perpetual Loyal forced to retire with hull damage *Feature
2014 Rolex Sydney Hobart: Clouds backs the small boats for overall win
Rolex Sydney to Hobart: Replay video coverage on Sail-World *Feature
Sydney Hobart - Comanche leads but Oats XI keeps the rubber band on
Will Comanche take a scalp?
Rolex Sydney Hobart Yacht Race 2014- Southerly takes its toll
Rolex Sydney Hobart: Comanche leads in softening morning breeze *Feature
Rolex Sydney Hobart - Comanche take a gun to the knife fight + Video
Rolex Sydney Hobart Yacht Race 2014 - Supermaxi contest + Video
Rolex Sydney Hobart: Images from the flying start on Sydney harbour
Rolex Sydney Hobart Yacht Race 2014: Start photos by Andrea Francolini
Sydney Hobart 2014 The Cutting edge Formula 1 yacht still leads
Rolex Sydney Hobart Yacht Race 2014 – Grand dame heads back to Sydney
Rolex Sydney Hobart Yacht Race - Day 1 start images by Carlo Borlenghi
Rolex Sydney Hobart: Race Start Images by Crosbie Lorimer *Feature
Clipper Ventures 10 starts Rolex Sydney Hobart Yacht Race
Rolex Sydney Hobart Yacht Race - Another year another record
Rolex Sydney Hobart 2014 – Comanche on the warpath
2014 Rolex Sydney Hobart - Spithill to grind on Comanche
Rolex Sydney Hobart Yacht Race – Spinnaker start forecast
Rolex Sydney Hobart Yacht Race - Wild Oats XI ready to go   
Adventures of a Sailor Girl: Hobart coverage - December 26 - Live   
Rolex Sydney Hobart - The Peyron Perspective -Old People On New Boats *Feature   
2014 Rolex Sydney Hobart - Spithill to grind on Comanche   
Rolex Sydney Hobart; Wild Oats XI trials Goose for Christmas   
Rolex Sydney Hobart Yacht Race 2014 - The Weather Gate *Feature   
For Christmas a Shiny new Sail-World.com *Feature   
Sydney-Hobart: Wacky Races 3 – Gravel and Red Max versus VMG *Feature   
Yankees at the Gate - A pre Sydney-Hobart conversation with Ken Read *Feature   
Rolex Sydney Hobart: Line Honours Skippers Press Conference - Video   
Barcelona World Race 2014-15 -A different Christmas   
Volvo Ocean Race: Team Vestas Wind recovery video *Feature   
Rolex Sydney Hobart Yacht Race 2014 - Another great journey south   
Sydney Hobart - Ragamuffin's David Witt explains deck failure + Video   
Wild Oats XI - Damage drama in lead-up to Sydney Hobart Race   
Rolex Sydney Hobart Yacht Race images by Photographer Carlo Borlenghi   
Five faces behind the 100ft super maxis by Andrea Francolini   
2014 Rolex Sydney Hobart Yacht Race - Everyone's in with a chance   
Comanche Designers talk before Sydney Hobart   
Olympic Sailing Waters - Rio de Janeiro   


For this week's complete news stories select    Last 7 Days
   Search All News
For last month's complete news stories select    Last 30 Days
   Archive News







Sail-World.com  


















Switch Default Region to:

Social Media

Asia

Australia

Canada

Europe

New Zealand

United Kingdom


http://www.sail-world.com/event_images/image/Twitter_logo_small.png http://www.sail-world.com/event_images/image/FaceBook-icon.png  http://www.sail-world.com/event_images/image/RSS-Icon.png

United States

Cruising Northern

Cruising Southern

MarineBusiness World

PowerBoat World

FishingBoating World

 

Contact

Commercial

News

Search

Contact Us

Advertisers Information

Submit news/events

Search Stories/Text

Feedback

Advertisers Directory

Newsletter Archive

Photo Gallery

 

Banner Advertising Details

Newsletter Subscribe

Video Gallery

Policies

 

 

 

Privacy Policy

 

 


Cookie Policy

 

 



This site and its contents are © Copyright TetraMedia and/or the original author, photographer etc. All Rights Reserved.  Photographs are copyright by law.  If you wish to use or buy a photograph contact the photographer directly.
XLXL NEW US
LocalAds   DE  ES  FR  IT