The Sportsman Insider: Finalizing the Open 402 Ahead of FLIBS 2025

Progress on the all-new Open 402 is moving full speed ahead as the team prepares for its debut at the Fort Lauderdale International Boat Show. Since our last update, every area of the boat has seen major advancements as the prototype edges closer to completion.

Critical Installations Underway

The latest phase of the build focused on installing key elements that define both form and function. The new console, leaning post, hardtop, and front windshield glass are now in place. At the rear cockpit, the bilge has been fully outfitted with a Seakeeper 4.5 and generator. Lids throughout the boat have been fitted and covered, rub rail added to the hull, and for the first time the entire electrical system was powered on. With electronics alive across the helm, the crew could begin checking every connection and fine-tuning all the systems onboard.

Before the hardtop shell went up, the team carefully measured and rigged everything from antennas to Starlink and radar. This precision ensures that each component matches perfectly with its CAD design. Once complete, the hardtop was lifted into place and secured on the frame legs of the Open 402.

Upholstery and Interior Finish

Upholstery is one of the most important finishing touches, bringing both comfort and refinement. Without templates to rely on in the prototyping stage, each cushion was measured and fitted by hand. To achieve a flawless alignment, the crew used a clever technique: laying painter’s tape over lids, pressing cushions into place, and drilling exact pilot holes based on the impressions left behind. From there, recessed magnetic mounts were cut and cushions installed. This process was repeated across the chase lounge and the wraparound bolsters, ensuring a seamless fit throughout the cockpit.

Next-Level Visibility

As part of Sportsman’s 3.0 design language, the Open 402 introduces a brand-new panoramic seamless tempered glass windshield. This innovation delivers nearly a 35% improvement in visibility for the captain. The installation process began with cleaning and prepping the fiberglass, applying primer and sealant, and carefully lowering the curved glass into place with suction cups and ratchet straps. The result is a stunning, nearly seamless edge where the front and side windows meet.

Complementing this new windshield are the chase lounge windows, which flood the interior with natural light. Before installation, the fiberglass cutouts were sanded, painted, and buffed to create smooth edges, then finished glass was carefully set into place.

On the Road to FLIBS

From major mechanical systems to refined upholstery details, every step brings the Open 402 closer to its public debut. With final touches wrapping up, the flagship of the Open Series is nearly ready to hit the road for FLIBS 2025, where it will be revealed to the world.

Stay tuned to The Sportsman Insider for more updates and exclusive behind-the-scenes coverage as the Open 402 nears its grand introduction.