Where technology and old world craftsmanship meet.

Using state of the art cad cam software our naval architects create cutting edge designs that will take you well into the 21st century. Couple this with our modern plant and 30 years experience hand building pleasure crafts it becomes easy to see the Doral difference. Boats built for boaters by boaters with safety and enjoyment in mind. Whatever your fancy from a 17' runabout to our 36' flagship, Doral has the model for you for water-skiing, fishing or cruising. Before you make a choice see the Doral difference.

In life, it's the little things that set us apart from the rest. At Doral, not only do we strive to ensure that all cruisers and sport boats stand the test of time but as a Doral owner you will appreciate the "little extra touches" that we have integrated into our boats to meet and exceed your expectations. Step aboard, and you will sense the quality that can only be achieved through our commitment to superior engineering and construction techniques.

Perfection in Progress - Sport Boats

Purchasing a sport boat. The production process of a Doral starts the day of its purchase by its future owner. Each Doral boat is tailored to the specific client.

Planning: Purchasing of raw materials and production organization

The second step is to plan the production of the boat. Using production and inventory management software, materials are purchased and the workforce is organized. Most of the main components are custom-made to meet the client's specifications.

Start of production

The boat is produced in separate modules and then assembled in our various departments and workshops. Production of seat cushions, cabinets and composite parts start simultaneously with a large number of people working on the same boat at one time.

Sub-contractor network

The Doral production plant relies on a qualified and experienced network of subcontractors. Stainless steel work, canvas enclosures, electronic and electrical systems, are the produced by our experienced team of sub-contractors.

Fiberglass Department

The sandwich construction method used by Doral for all the main components of its boats ensures that they are stiffer, heat and sound insulated as well as lightweight. This method is widely used for racing yachts, aeronautics or Formula 1 racing. Doral hulls are all produced using a lay-up moulding and hand-laminating process.

Summary of composite construction process of the hull:

• We begin the hull with an 18 to 24 mm 953 Series C.C.P. gel coat.
• A 20 mm Sojel barrier coat is applied to create a water tight seal for protection against osmosis.
• The first layer of 1-1/2 to 2 oz chopped strand mat (C.C.P. Resin) skin coat is applied and allowed to cure.
• A second layer of 4 oz chopped strand mat is applied.
• A layer of 18 or 24 oz woven roving (depending on model size) between the second and final third layer of 2 oz chop strand mat for rigidity.
• The third layer of 2 oz chopped strand mat is applied.
• A final layer of 18 or 24 oz woven roving for maximum strength and rigidity is applied.

Cutting Department

Each composite part is cut out using templates and plans based on Doral's Design Team specifications. The parts produced by the cutting department are then ready to be assembled.

Upholstery Department

Doral has its own seat furnishings department. We manufacture the seats of our sport boats using the very best materials available. The frames of our cockpit seats are made from composite or rot-proof plastic. As well, all of the vinyl used is of superior quality and protected with UV and stain resistant films.

Assembly Line

The liner is attached to the hull using a Plexus bonding system (one of the strongest bonding agents available), which ensures complete bonding of the liner to the hull, thereby reinforcing the boatís stiffness. The liner serves many purposes:

• It provides a location for each part of the cabin and guarantees an accurate and constant assembly.
• It increases the boat's stiffness.
• It provides a fiberglass floor that is easy to clean and completely rot-proof.

The main composite parts (hull, deck and floor liner) are delivered to final assembly upon leaving the cutting department. Two assembly lines receive the deck and hull / liner. This production method ensures a quick assembly.

The engine and plumbing are assembled on the hull line. At the same time, the deck is pre-wired and all electrical, controls and hardware are connected and installed.

The fittings used are custom-made using only the finest quality materials such as 316 stainless steel. Once the deck is assembled, it is positioned on the hull.

The boat is nearing the finishing phase and the last of the plumbing or electrical connections between the deck and the hull are made. The interior and exterior seat cushions are installed along with the pinstripe accents and exterior canvas. The boat is now ready for the final inspection and testing.

Quality Inspection and Tests

The Quality Assurance Department will take over for the testing phase. At Doral Boats, we have implemented a QA-Pass system, where any component must receive a QA-Pass from Quality Assurance (QA) before proceeding to the next stage in the manufacturing pipeline. This allows us to identify any deficiency early during construction, and correct it before it becomes a problem.

In the lamination department we test for curing, gel time, trapped air, and tensile strength of composites. We also test gelcoat thickness with a wet film thickness tester, fineness and thickness of laminate with a glass meter, and the gelcoat finish with a UV black-light that shows fine lines or fractures. QA will not issue a QA-Pass if any testing criteria are not completely met.

Upholstery is tested during fabrication for dimensional accuracy, correct stitching, and foam bonding before being given to QA for inspection. QA must approve each piece before it is given a QA-Pass and installed in a boat.

When the boat finally reaches the end of the line, we once again test all systems and compare it against our prototype. We perform mechanical tests and start the engine to ensure everything is flawless. All electrical systems are tested and calibrated. The boat goes through a high pressure shower to test for any leaks around portals, fittings, or screws. We even go so far as to water test about every 10th boat. Once the boat passes every stage, it then receives the Doral Quality logo and is shipped off to the dealer.

Perfection in Progress - Express Cruisers

Purchasing a Cruiser. The production process of a Doral starts the day of purchase by its future owner. Each Doral boat is tailored to the client's needs.

Planning: Purchasing of Raw Materials and Production Organization

The second step is to plan the production of the boat. Using production and inventory management software, materials are purchased and the workforce is organized. Most of the main components are made custom to meet the client's specifications.

Start of Production

The boat is produced in separate modules and then assembled in our various departments and workshops. Production of seat cushions, cabinets and composite parts start simultaneously with a large number of people working on the same boat at one time.

Sub-contractor Network

The Doral production plant relies on a network of qualified and experienced subcontractors. Stainless steel work, thermo-forming technology, aluminum tank manufacturing, electronic and electrical systems, varnishing and woodworking are all the results of our experienced team of sub-contractors.

Fiberglass Department

The sandwich construction method used by Doral for all the main components of its boats ensures that they are rigid, heat and sound insulated as well as lightweight. This method is widely used for racing yachts, aeronautics or Formula-1 racing. All Doral hulls are produced using a lay-up moulding and hand-laminating process.

Composite Construction Process of Hull:

• Gel coat 18 to 22 mil (dependent upon where the gel is going to be applied)
• Vinyl ester barrier layer over entire surface of the hull. This will protect your boat against osmosis and provides a superior quality finish.
• First application: Type E glass mat and polyester resin. Lay-up moulding.
• Second application: Type E glass mat reinforced with type E sewn fiberglass fabric.
• Third application: Type E glass mat reinforced with type E sewn fiberglass fabric for over-exposed surfaces.
• Fourth application: The core material is applied using a polyester bond and a vibrating roller; this ensures the glue's complete penetration.
• Fifth application: Type E glass mat reinforced with type E sewn fiberglass fabric.
• Sixth application: Type E glass mat reinforced with type E sewn fiberglass fabric on over-exposed surfaces.
• Seventh application: Layering of the boat's structural frame. Each Doral hull consists of a rigid pre-assembled structural frame. The frame is positioned in the hull and then layered into the hull using glass mat and braided roving or sewn structured fabric.
• Eighth application: A final gel coat is applied to the interior of the hull.

Cutting Department

Each composite part is cut out using templates and plans based on the client's specifications. The parts produced by the cutting department are then ready to be assembled.

Cabinet Department

• Vacuum bench: All interior wood cabinets at Doral are produced on our vacuum benches. Materials are glued together in a vacuum using a water-resistant bonding agent. As a result, we are able to produce modern furniture that is both unique and stylish.
• Numerical control robot: Each furniture part is cut out using a numerical control robot. This process ensures extraordinary quality and accuracy. Using top of the line software and digitizer tables, the computer department supplies the operator with the cutting diagrams that meet the future owner's requirements.
• Qualified workforce: The furniture assembly is entrusted to experienced craftsmen who, using Doral's unique assembly processes create the most sophisticated furnishings in North America.
• Glossy varnish: The varnished wood cabinets on Doral cruisers and yachts, are given a glossy polyester and polyurethane finish. Between 7 and 9 successive layers are applied to achieve this unique finish.

Upholstery Department

Doral has its own seat furnishings department. We manufacture the seats of our cruisers using the very best materials available. The frames of our cockpit seats are made from composite or plastic. As well, all of the vinyl used is of superior quality and protected with UV and stain resistant films. We also produce our own bed ensembles, curtains and pillows using mostly European fabric chosen by our interior designers.

Assembly Line

Upon leaving the cutting department, the main composite parts (hull, deck & cabin floor liner) are delivered to the assembly lines. This production method insures consistent superior quality assembly.

The engine, electrical systems and plumbing are assembled on the hull line. At the same time, the cabin liner is pre-assembled and then installed in the hull. The cabin liner is attached to the hull using a Plexus bonding system (one of the strongest bonding agents available), which ensures complete bonding of the liner to the hull, thereby reinforcing the boat's rigidity.

The liner serves many purposes:

• It provides a location for each part of the cabin and guarantees an accurate and constant assembly.
• It increases the rigidity of the boat.
• It provides a fiberglass floor that is easy to clean and completely rot-proof.

The boat is nearing the finishing phase and the last of the plumbing or electrical connections between the deck and the hull are made. The interior and exterior seat cushions are installed along with the pinstripe accents and exterior canvas. The boat is now ready for the final inspection and testing.

Quality Inspection and Tests

The Quality Assurance Department will take over for the testing phase. The boat is first subject to a water test using high-pressure showers. These showers are placed around the vessel in key locations. High-pressure water is then emitted for several hours and the quality assurance team inspects it afterwards for any water infiltration. The team then checks all of the systems including water pressure, shower and electrical. The engines and all electrical and mechanical systems are also subjected to operating tests. After the quality assurance inspectors have given their approval, the boat is packaged and delivered to its future owner.