EPISODE 8

Regal Boats FACTORY TOUR: How Boats are Made

In this episode of From 100 to 26, we travel to Orlando, Florida to one of the few family owned and operated U.S. based boat manufacturers. Founded in 1969 by Paul and Carol Kuck with a vision of innovation and customer satisfaction, they formed a legacy and defined a new standard in boating luxury. More than fifty years later,the award winning family owned company has grown to become a leading player in the boating industry.

During our factory tour, Jake Kuck, one of the owners and the Vice President of North American Sales and Marketing, spends a full day with us as we go through an in-depth walkthrough of the entire 650,000 square foot facility where over 900 team members work everyday creating Regal Boats. The Orlando based manufacturing facility builds almost 1500 Regal Boats per year! Today, Regal Boats is ranked highest in customer satisfaction by both JD Power and Associates and the National Marine Manufacturers' Association.

Out on the production line we see the full gamut of Regal Boats attention to detail across various assembly lines and all the detailed processes that go into constructing the brand's current models - from the largest outboard luxury yachts on the market (such as the 42XO) to their smallest bowriders, all of the boats receive the same level of attention to detail. With almost everything made in-house including all cushions, cabinets, wiring harnesses, etc. it is an incredible process to see in their state of the art facility.

Regal Boat uses cutting edge technology such as CNC machines (computer numerical control machines) to ensure every various components from seat cushions to cabinetry are cut to perfection every single time.

We were also blown away by how Regal Boats puts color on the hulls of their boats. Unlike other boat manufacturers, Regal does not use paint when it comes to the color of their hulls; rather, they use colored fiberglass. The color is actually poured into the fiberglass during the manufacturing process. This makes for an extremely durable, long lasting finish.

And finally, the most exciting part of our visit was seeing the innovative technique Regal Boats uses when assembling their boats. Instead of using stick construction which means little parts of the interior are assembled one part at a time, Regal uses a solid fiberglass liner where the entire interior is assembled on this rigid fiberglass floor, including all wiring, plumbing, cabinets, beds, etc, then this entire assembly is flown over by crane and placed into the hull where all the tanks and electrical components have already been installed. This liner the then set into the hull and the deck on top of the liner to finish the assembly, simply cutting edge technology.

Timecodes

0:00 - Intro
1:56 - Jake Kuck Vice President North American Sales & Marketing of Regal Boats Interview
4:47 - The Lamination Process & Building the Boat
10:05 - Wiring the Boat & Making It All Work
15:15 - Boat Seat Cushions Design & Fabrication
21:33 - Boat Cabinetry Design & Fabrication
23:20 - Small Boat Assembly — Building the Boat
26:14 - Big Boat Final Assembly — Building the Boat
30:54 - Sneak Peak of Our New Regal Boat 38XO

In case you’re just joining us, here is a direct link to our channel where you can view our first 7 episodes

https://youtube.com/@From100to26?si=I...

Below are direct links to each episode:

Episode 1 • The BRAVO Chronicles: Our Adventure on a 100’ Yacht

   • (Ep 1) The BRAVO Chronicles: Our Adve...  

Episode 2 • Conquering the Waves: BRAVO’S Trip from Florida to Maryland

   • (Ep 2) Conquering the Waves: BRAVO’S ...  

Episode 3 • Unfortunate Mishap: Motor Yacht BRAVO’S Costly Run-In with a Boulder

   • (Ep 3) Unfortunate Mishap: Motor Yach...  

Episode 4 • 100’ Yacht BRAVO Departure Preparations

   • (Ep 4) 100’ Yacht BRAVO Departure Pre...  

Episode 5 • 100’ Yacht Bravo’s WORST Trip Ever! Massive Waves & Sea Sickness

   • (Ep 5) 100’ Yacht Bravo’s WORST Trip ...  

Episode 6 • 100’ BRAVO Yacht Crew: The Good The Bad The Ugly

   • (Ep 6) 100’ BRAVO Yacht Crew: The Goo...  

Episode 7 • From 100’ Yacht BRAVO to a Regal 26 XO… for THREE weeks!

   • (Ep 7) From 100’ Yacht BRAVO to a Reg...  

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