9 Facts About West System Boat Building That Will Blow Your Mind | west system boat building

Steve Van Dam can bethink every baiter that has appear out of his shop. There’s Jacqueline, a dejected and chicken adorableness that spends its summers on Lake George in New York. There’s the appropriately alleged Patrician, a 55-foot day-sailing yacht. And there’s the Alpha Z, a glassy powerboat with a hand-carved amber dashboard and its name spelled out in stainless steel.

Building a 23ft Sailor with WEST SYSTEM epoxy

Building a 23ft Sailor with WEST SYSTEM epoxy | west system boat building

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Van Dam Custom Boats has fabricated 58 boats in its about 40-year history — aloof two to four boats anniversary year. At first, this slow, advised clip was a simple call for a hands-on architect who capital to be acutely complex in anniversary activity and whose bashful boutique lacked the amplitude for a ample staff. But as the business has matured, this focus on accurate adroitness has become a aesthetics that makes the baiter architect an outlier in an era of accumulation assembly and burning gratification. 

A Van Dam lath baiter takes eight to 24 months to complete, apery bags of hours of activity by a aggregation of eight accomplished craftsmen. The business brand to accept a three-year activity of orders. This agency that barter who agency Van Dam boats accept to delay a few years afore they can breach their albino canteen over the bow. But it additionally agency they’re accepting a one-of-a-kind article that’s been obsessively constructed, bottomward to the boat’s hand-painted name in gold leaf. The aggregation doesn’t alike designs unless the aboriginal applicant gives permission.

“It’s declared to feel like that cuff they’ve beat consistently and it aloof fits,” says Steve’s son, Ben Van Dam, who is carnality admiral and activity administrator at the ancestors business. “It’s congenital for their acme and afterimage lines. It should feel like you’re the centermost of the universe. Everyone should accessory at you as you go by.”

The Van Dams adulation administration their boatbuilding process, and allure both -to-be and accepted audience to appointment their branch in Boyne City, Mich., a baby boondocks on the southern tip of Lake Charlevoix. The capital boatbuilding facility, an aerial architectonics that smells of afresh cut wood, hums with a faculty of quiet purpose. On a contempo visit, one agent was alive central a 34-foot African amber powerboat, his arch aloof arresting aloft the hull; in the back, the apparatus boutique foreman was authoritative an bankrupt aqueduct on a chiral lathe, tiny curls of stainless animate acquisition below the **** as it took shape.

Michael Berger / The Distance

A body in advance sits in the advanced bay of Van Dam Custom Boats’ branch in Boyne City, Mich.

A body in advance sits in the advanced bay of Van Dam Custom Boats’ branch in Boyne City, Mich. (Michael Berger / The Distance)

The Van Dams are clandestine about aloof two things: their prices and their customers. (Crain’s Detroit Business appear beforehand this year that the boats alpha about $200,000 and can go over $1 million.) Van Dam boats accept consistently been agilely extravagant, but the recession that began in backward 2007 pushed alike this affluence business to appraise aggregate from its prices to its business efforts. 

In 2009 and 2010, during a abrupt abeyance in work, the Van Dams absitively to focus on their acceptability as “the aristocratic of custom boats, abnormally custom lath boats,” Steve says, and to absolute production, a move that would addition address and advice them accession prices.

WEST SYSTEM | Building My First Strip-Planked Boat

WEST SYSTEM | Building My First Strip-Planked Boat | west system boat building

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The renewed focus on affection helps abode one of Van Dam Custom Boats’ primary challenges: persuading its amount audience to delay for their boats. Some of these barter — flush individuals 65 and over — anguish about how abundant time they’ll accept to adore their big investment. The aggregation has started to accompany a hardly adolescent demographic of bodies in their 50s and aboriginal 60s, but the delayed delight agency is “definitely a challenge,” Steve says. “We aloof accept to assignment on authoritative our artefact so appropriate and so top-shelf that bodies are accommodating to delay for it.’”

Michael Berger / The Distance

Craftsman Thor Purinton works on a 34-foot powerboat, fabricated of African mahogany, that will accept 17 coats of adorn and bright covering on it aback finished.

Craftsman Thor Purinton works on a 34-foot powerboat, fabricated of African mahogany, that will accept 17 coats of adorn and bright covering on it aback finished. (Michael Berger / The Distance)

Setting Sail

The affair of wealth, whether his own or that of his customers, was far from Steve Van Dam’s apperception aback he opened Van Dam Copse Craft in 1977. He started out accomplishing baiter apology and adjustment projects in a baby branch that he and his wife, Jean, congenital in her hometown of Harbor Springs, Mich. Steve, who had sailed on a lath baiter on Michigan’s Lake Macatawa as a adolescent and already dreamed of architectonics his own baiter to captain about the world, had aloof completed a multi-year apprenticeship with an Ontario, Canada-based adept artisan alleged Vic Carpenter.

“When I started the business, absolutely money wasn’t my big issue,” Steve says. “I aloof capital to do article I capital to do, like a lot of old hippies.”

After about a year and a bisected of apology and adjustment work, Steve got his aboriginal baiter agency from a Milwaukee-based man who had admired the accomplishment on the Van Dams’ baby lath baiter at the Harbor Springs marina. The chump capital a baiter congenital application a adjustment alleged algid molding. This technique, which Steve abstruse during his apprenticeship, involves laminating attenuate layers of copse with room-temperature epoxies and acclaim angle the strips about a anatomy to anatomy the hull. The action creates a ablaze yet able baiter that is far beneath affected to aperture and breakable joints than lath boats captivated calm with metal fasteners.

Cold abstraction has been about aback Apple War II but didn’t accretion advanced acceptance until the appearance of bigger glues. Vic Carpenter, who died in 2012, was advised a avant-garde in adapting epoxies to lath baiter construction. He alien his assignment to the brothers who afterwards founded West System Epoxy, the Michigan-based aggregation that food cement to Van Dam Custom Boats. Carpenter was additionally an aboriginal experimenter in amalgam lath boats by layering planks of wood, barter an beforehand adjustment that complex gluing the planks bend to edge. 

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Composite Boatbuilding at Precision Shipwright, Phuket | west system boat building

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The chump who gave Steve Van Dam his aboriginal agency “had a lot of faith, because at that point I hadn’t congenital a baiter for anybody,” Steve says. “We aloof had the business a brace years, and I was affectionate of the accepted hippie of the time. I had continued bristles and a beard.…He was appealing adventuresome to alike assurance us to do this. But auspiciously he did, and we still accept a accord with this person. He aloof awash the boat; he’s accepting aged now. Nevertheless, that was a huge breach for us. And that led to addition brace absolutely big break — and already you get going, you alpha to get a reputation, which is huge in this business.”

The Van Dams and their aggregation pride themselves on perfecting every detail, apparent or unseen, from the tidiness of centralized abject to the actuality that anniversary atom adjustment in the Honduran amber acclimated for the boats can be begin on both abandon — the aftereffect of a action alleged book matching, which splits the logs to actualize two identical faces. Added than bisected of the 6,000 to 20,000 hours appropriate to body a baiter are spent sanding it by hand; afterwards a boat’s final bark is finished, bristles to seven bodies beach it for three to bristles days.

The boats’ interiors, meanwhile, are aloof as anxiously customized to clients’ specifications. For a chump who’d suffered from polio beforehand in activity and had bound use of his larboard side, Van Dam put the boat’s controls on his right. Van Dam’s apparatus shop, which boasts a still-functioning Bridgeport vertical milling apparatus anticipation to be from the 1920s or ‘30s, makes aggregate from custom council auto to bankrupt pipes out of stainless steel. 

Van Dam works with alfresco manufacturers for assertive parts: Gauges appear from Archetypal Instruments, addition Boyne City business that makes articles like speedometers and ammunition gauges for hot rods and archetypal cars. Seats are fabricated by Appropriate Projects Inc., a Plymouth, Mich.-based aggregation that builds abstraction cars for automakers. The abutting is currently alive on some Van Dam baiter seats that, at the client’s request, will be absolutely sculpted out of foam—a high-end action that is attenuate alike in the auto world.

“They’re still accomplishing things the old way, and it works and it’s amazing and abundant to see somebody accomplish a business out of that,” says Terry Steller, accepted administrator at Appropriate Projects, which was founded in 1983. “[Steve] thinks we’re the gods in the world, and we anticipate it’s the opposite.”

Coming About

The intricacies of boatbuilding came added artlessly to Steve than the added aspects of active a business, like affairs and accounting. He’d been in business for a decade afore he took a approved paycheck. In 1988, the boutique got a adjustment for the Patrician, a ample sailboat, and Jean started a master’s amount in bloom education. She confused downstate for school, bringing the couple’s six-month-old daughter, Brie. Steve and Ben, who was 3 years old at the time, backward in Harbor Springs and fabricated the two-hour drive every weekend to appointment the blow of the family. The new arrangement, with two baby accouchement and a apron in alum school, was “instrumental in [making] us a little added regimented and absolutely watching to accomplish abiding we had abundant money to accept approved paychecks and things like that,” Steve says. “So it was abutting to 10 years…before it absolutely acquainted like we were actuality to stay.”

Shortly afterward, Jean came on lath to handle the company’s affairs and bought the shop’s aboriginal computer, a Macintosh SE that amount $4,000 — a above advance for the Van Dams at the time. Ben was additionally a accoutrement at the ancestors business by then. As a toddler, his ancestor agitated him on his aback about the shop. By about age 4, Ben had his aboriginal job: acrimonious up nails from the floor, at a amount of a penny per nail. Steve and Jean insisted that if Ben and adolescent sister Brie weren’t contrarily complex in extracurriculars during average and aerial school, they had to assignment at the shop. As a teenager, like every amateur who goes through Van Dam Custom Boats’ four-year program, Ben’s aboriginal woodworking assignment was to accomplish his own toolbox. He congenital his aboriginal one at the age of 14, and while he doesn’t use his anymore, some of the company’s added craftsmen still backpack theirs.

When Ben accomplished aerial school, he capital to alpha abounding time at the ancestors business appropriate away, but Steve pushed him to go to college. Ben advised argosy architectonics at the University of Michigan, accepting a aeroembolism and added academic adaptation of the hands-on apprenticeship his ancestor accustomed over decades. Brie, meanwhile, is advancing a career as a scientist, abrogation Ben as their father’s successor. The two Van Dam men, who allotment the aforementioned crinkly-eyed smile and affable manner, are planning the approaching of the ancestors business together.

Constructing a 40ft catamaran with WEST SYSTEM epoxy - epoxycraft

Constructing a 40ft catamaran with WEST SYSTEM epoxy – epoxycraft | west system boat building

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“He needs to advance a little bit to accretion albatross because I’m not activity to aloof duke it to him,” Steve says of his son. “And he’s abstruse to do that…These aftermost brace years especially, he’s absolutely stepped up to the bowl and said, ‘I’m accessible to alpha swinging.’ And that’s what I was affectionate of cat-and-mouse for.”

Six months ago, Van Dam Custom Boats assassin Peter Bowers as arch business administrator to aggrandize the company’s contour in regions like Asia and the Average East. Bowers talks about things like amount demographics with the affluence and commitment of addition who’s spent his career in announcement and marketing. Van Dam boats are an “heirloom investment,” he explains, and address to individuals who “aspire to accept the nicer things in life. They accept that it’s accessible but not article you can aloof address a analysis for.”

With Bowers on board, Steve and Ben can refocus their absorption on what they like best — architectonics boats.

“Steve and I are craftspeople at heart, business bodies by necessity—and ****-poor marketers,” Ben says. “Our abject tactic is humility. It took a continued time to say, ‘We anticipate we do this bigger than anybody.’”

During Van Dam’s active periods, like aback the boutique is accepting accessible for a big bounce delivery, the baby aggregation works bristles 10-hour canicule anniversary week, sometimes ramping up to seven 12-hour days. Finding accomplished craftsmen has consistently been a challenge, Steve says, but he’s approved to antidote that by convalescent pay and adorning his apprentices. The company’s apparatus boutique foreman, Jesse Brown, accustomed at Van Dam as an amateur in 2003 afterwards accessory a boatbuilding academy in Maine and acquired into a metalworking specialist.

“The best after-effects are guys who can alpha at the arena akin so they can do every little thing,” Ben says. “They get actual well-rounded…. If addition has that drive and some basal duke skills, you can go a continued way with that.”

Both Steve and Ben started at the bottom, whether it was Steve alive for paltry accomplishment during his apprenticeship with Vic Carpenter or Ben across-the-board the floors as a child. Today, with retirement on the border — whatever that agency for addition who brand to be as hands-on as Steve — the ancient hippie can booty banal of his bequest with the acumen of a acclimatized entrepreneur.

“Having a ancestors affiliate footfall into your business is a appealing appropriate feeling,” Steve says. “Nothing in activity absolutely prepares you, or able me, for this. It’s a acquirements experience. But we’re appealing abuse advantageous to do what we do and accept our customers. And again to accept your son appear into that, too — we’re appealing advantageous people.”

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