Development Update #2 on the Pulse 600

Following up from our last Pulse 600 development update where the male float plug had just been sprayed with the green tooling gelcoat, we now see the female mould being completed through to its final stages.

Once the tooling gelcoat is applied and hardened, a fine layer of fiberglass is then carefully applied by hand to back-up the gelcoat so that the mould shape is firm before the bulk of the mould laminate is applied. This initial layer is very critical as it defines the shape and finish of the parts that will come out of the mould in the future.

After the fine GRP layer is applied, further layers are then added to really add strength to the mould shape so that the dimensions and finish of future parts are consistent time after time. The mould also has to have enough strength to easily withstand the lamination and demoulding process for continuous production in a factory environment.





As seen in the image to the left, once the glass work is complete on the mould, with the plug still inside, a steel framework is cut and welded on the mould. This frame work is then glassed onto the mould. This allows the production team to be able to move the moulds around easily on casters, have lifting points in order to demould and also provide a framework to support the mould at an ergonomic height to work on whilst the parts are being laminated.





With the centerline split mould having been completed on both sides and frames work attached, the plug is now ready for demoulding (as seen in image below).


There’s always a little suspense when demoulding new moulds however as planned, the gelcoat surfaces of the two moulds come out with an excellent result and the moulds with very quickly be able to produce the first set of Pulse 600 floats (as seen in image below). The factory foreman responsible for this area of production has now worked for Corsair for over 10 years, as have many of his team, and these guys have literally built hundreds of moulds of various shapes and sizes so the quality of the work is of an extremely high standard.


From this point forward the male plug has no further purpose for this mould, however it will be kept so that a second set of float moulds can be made following the on water testing of the prototype Pulse 600 at the beginning of 2015.

That’s it!

Float moulds - Done
Beam moulds - Done
Hull mould - Done

Now we are focussing on the deck plug which is well and truly underway. The purpose of the male deck plug is obviously to create a surface from which a female deck mould can be taken however it is also the critical point at which we double check that what has been designed in the 3D modeling process actually works in terms of ergonomics, functionality deck layout/running rigging and of course, aesthetics…


Be the first to sail the new Pulse 600

Here are the development updates so far...

Introducing the Pulse >>

Development Update #1 >>

Development Update #3 >>

Development Update #4 >>

Development Update #5 >>

Development Update #6 >>

Development Update #7 >>

Development Update #8 >>

Development Update #9 >>

Development Update #10 >>

​Development Update #11 >>

​Development Update #12 >>

Keep me up-to-date

View Pulse 600 Photos >>

View Pulse 600 Brochure >>

Worldwide Pulse Performance Centers >>



Comments for Development Update #2 on the Pulse 600

Name: Jurgen Zimmermann
Time: Thursday, October 30, 2014

Very interesting and fun to follow the Action as closely as this.

Name: Mike Rees - Team Corsair
Time: Friday, October 31, 2014

Hi Jurgen,

I hope that you have had a fantastic summer in Northern Germany onboard your Dash Mk II.

For most people, making the journey to do a factory tour is just too far so for this project we have decided to bring the factory to you...

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