Our Shop

Building a Better Boat

 

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Building the ChilKat 30

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  Spraying Gel Coat
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  Drawing down the vacuum bag
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  Resin begins to flow.
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  Watch that resin go!
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  Bow completely infused.
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  Stern infused.
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  Gel Coat in the hull mold
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  Hull mold on its side
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  Laminating the skin coat
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  Finishing skin coat
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  Installing fiberglass
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  Installing core
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  Core in the transom
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  Core complete
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  Next layers of glass
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  Reinforcing tape
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  Finsihing up the glass
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  Full vacuum
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  Ready for resin
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  The hull is infused
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  Bag pulled from hull
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  Making the decks
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  Another deck
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  Installing the decks
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  Infusing the house
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  House with windows cut
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  Installing the cap
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  Trimming the hull
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  The boat goes together
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  Yahoo!
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  Out of the shop!
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  Port view
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  Starboard view
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  Decals on
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  Into the water!!!

 

The ChilKat 30 is built using the Vacuum Infusion Process. Instead of hand laminating each part, all of our parts our made by first laying all of our fiberglass and core materials into the mold dry. When we are satisfied that the materials are laid out properly, we place a vacuum bag over the entire mold and then pull almost a full atmosphere of vacuum inside the bag. After this has been done and the bag has been checked for leaks we introduce the resin all at once into the part, flooding it in a matter of minutes. When the fiberglass has filled with resin we stop the flow and, retaining the vacuum, allow the part to fully cure inside the bag.

This innovative process not only insures uniformity from boat to boat but also means each boat we build has higher fiberglass to resin content, meaning you get a stronger, lighter boat. We build our boats using only the highest quality vinyl ester resins translating into the best end products. These methods not only produce a better boat, they also give us a better shop environment in which to work.

Company History

Black Feather Boats, located in Juneau Alaska, on the banks of the Mendenhall River, is unique because we are the only fiberglass / composites boatbuilding shop in Southeast Alaska, and the only shop in Alaska utilizing the Vacuum Infusion Process. Black Feather Boats was started in Homer Alaska in 1989. The emphasis of Black Feather Boats has actually been in 3 very different types of watercraft technology: new boat construction, local boat repair/ shipwright services, and further study and development of the many styles Native watercraft.

Company founder, Gregor Welpton had a vision of building boats and kayaks that were unique to Alaska’s heritage and coastal conditions.  During it’s early years, the company did commercial vessel repair, built skiffs and also built baidarkas for several museums and private owners.

Black Feather Boats has performed boat repairs on all types of wooden, fiberglass, steel and aluminum commercial and pleasure craft, from 8’ - 148’, using traditional and modern methods. Many of the commercial vessels serviced are still active in Alaskan fisheries, with gear types including pot fisheries, gillnet, seine, longline, commercial troll and dive fisheries. The list of repairs and refurbishments is quite numerous, but includes everything from extensive hull surgery in time sensitive environments to complete revamp of bridge, engineering and crew recreational areas on Bering Sea crab vessels.

Black Feather Boats has also done many commissioned works. Commissions have included vessels for the Pratt Museum as a centerpiece for their “Hunter and the Hunted” exhibit, the Alaska Native Heritage Center as part of their “Paddling into the New Millenium: Canoes and Qajaks of Alaska”, Fort Ross Interpretive Center, Jenner, CA.; Kunihiko Yasuda, Igenta Inc., Osaka Japan; U.S.F.S. Begich - Boggs Visitor Center , Portage AK.; and many other private owners.

Black Feather Boats relocated to Juneau , AK., since 1996 and was Incorporated in 2003.

Gregor Welpton

As the founder and President of Black Feather Boats, Gregor Welpton has been instrumental in bringing Vacuum Infusion technology into the Alaskan manufacturing marketplace.  Gregor brings a wealth of experience and energy into his business.  Professionally trained in the intricacies of wooden boat building and wooden boat repair, Gregor spent many years rebuilding decks, sterns, pilothouses, driving steam bent ribs and replanking older boats.  

His fascination with many different types of watercraft led him to study many of the traditional vessels of the Pacific, and eventually led him to work on several large dugout canoe projects and also build many of the traditional kayaks that are found throughout Alaska. Many of these boats can be seen hanging in museums, though he freely admits that his favorite ones are the working boats, the ones which still see water day to day.

Gregor ran the Marine Technology department at the University of Alaska, Southeast . As a teacher, Gregor’s enthusiasm spread to his students who took on many varied projects – from rebuilding masts to building fiberglass boats and rowing shells to lofting and developing new skiff designs that run particularly well in Southeast Alaskan waters.

Upon leaving the University, and after taking some time off to sail with his wife, Gregor returned to school in Kennebunkport Maine where he earned his Yacht Design degree from the Landing School . Upon completion of the program he took his skills to Italy where he worked for Victory Design , a small design house in Napoli, working on many different types of craft there. Customers he worked for there included the Ferretti Group, Cabi Cattaneo and Azimut.

Returning to the States, Gregor began working for the Coastwise Corporation , helping to design larger aluminum power catamarans for Allen Marine of Sitka.  He has many varied hobbies, is a Certified Diver, a Sailor,  and loves outdoor activities, including: hunting, fishing, camping, snowboarding, mushing and dogsled building, although most of his time these days is spent over seeing production of Black Feather Boats ChilKat 30.