Designing In Side Entry Doors - Sportsman's "Behind The Glass" (Season 3 - Episode 8)

When it comes to designing and building a boat, every detail matters. In the latest episode of Behind The Glass, we take you behind the scenes of our production process to showcase one of the most remarkable features found on Sportsman Boats 26 feet and above: dual side entry doors. These doors are not only a testament to our commitment to innovation and quality but also a prime example of the engineering precision and craftsmanship that sets Sportsman Boats apart.

Designing with Purpose

The creation of a side entry door starts long before production begins. During the initial design phase, our team works to ensure seamless integration and top-tier functionality. Unlike smaller boats with uninterrupted hull sides, boats with side doors require special provisions in their hull molds. These molds are engineered with precision to accommodate the additional framing and structural reinforcements necessary to support the door.

But we don’t stop at just functionality. At Sportsman, we finish our doors entirely in fiberglass, eliminating the need for the shiny stainless frames many other manufacturers use. The result? A sleek, uninterrupted profile that enhances the boat's overall aesthetic appeal and strengthens its structural integrity.

The Role of the Stringer System

Adding a side door to a boat presents unique engineering challenges. Cutting into the hull requires precise planning to maintain structural strength. That’s where our stringer system—a boat’s backbone—comes into play. The stringer and hull sides around the door are locked together, creating a robust support system that can withstand the forces and energy encountered on the water.

This system ensures that our boats remain as durable as they are visually stunning, reinforcing the door's frame with an I-beam-like structure that enhances strength and durability.

Innovative Manufacturing Techniques

The manufacturing process for these doors involves cutting-edge techniques like light RTM (Resin Transfer Molding). This method allows us to produce parts with gel-coated surfaces on both sides, ensuring a flawless finish inside and out. Using CNC-cut fiberglass for precise layering, we achieve an airtight mold that prevents resin leakage and maintains consistency across every piece.

To keep the door lightweight without compromising strength, we use foam core inserts molded specifically to fit the door cavity. This approach not only minimizes weight but also adds structural integrity.

Flawless Assembly and Installation

The final stages of production are all about detail. Each door undergoes a rigorous polishing, sanding, and finishing process to ensure a high-gloss, seamless look. The installation process is equally meticulous, with each door carefully aligned and bolted to maintain uniform gaps and a smooth swing. Our team checks every detail, from door alignment to hinge performance, ensuring the highest level of quality before the boat is delivered.

Redefining Standards in Boat Design

The dual side entry doors are more than just a functional feature—they’re a reflection of Sportsman’s dedication to quality, innovation, and craftsmanship. By prioritizing both aesthetics and structural integrity, we’ve created a feature that enhances not only the functionality of our boats but also their beauty and durability.

This episode of Behind The Glass highlights the incredible effort and expertise that go into every Sportsman boat, reaffirming our commitment to creating the fastest-growing line of center console and bay boats in the market.

Don’t Miss Out

For more behind-the-scenes insights, make sure to catch the latest episode of Behind The Glass. Stay tuned as we continue to showcase the processes and passion that define Sportsman Boats.

For exclusive content and details, visit the official Behind The Glass page:
https://www.sportsmanboatsmfg.com/btg