The Mould Table for KSS

We are proud to offer KSS's unique advantages to our clients. Those clients range from the most experienced professionals to the novice building their first boat. KSS is the method of custom boat building which is applied to all Kelsall and non-Kelsall designs.

Having pioneered the use of foam/fiberglass sandwich construction, Kelsall Catamarans has continued to develop and refine the use of these materials. KSS is the only build method to have ever been subject to regular development and is more efficient than any alternative.


Why apply liquid to an angled surface when most if not all can be done on the flat – and then pick up a smooth finish on a full size part, which has to take a fair line? WIth KSS all main laminating is done off the boat.

The simplest table surface and the one we recommend for a one-off project, is based on sheets of melamine covered chipboard or MDF. The pictures are of the table made for the Colorado workshop. It took 2 hours and $120 to make. Sheets of good quality melamine are butt joined, with plenty of white wood glue and resting on trestles. The table used for workshops and R&D at the home office in Waihi, NZ was made 7 years ago. It is a Formica surface and has had a lot of wear and tear. Everyone who sees the gel coat surface on the hulls says “I would be happy with that”.

There is a choice of finish to the melamine. Gloss or very slightly patterned. If planning to remain with the finish from the table, the gloss is best. If planning to use sandable gel coat and go for the high quality paint finish, the slight pattern works well and gets removed, along with any print through while preparing for painting. When using a white gel coat, which will be the final finish, it is preferable to use a colored surface. It will show up any thin areas of gel which would show through on the final panel.

Where a table is to be used for more than one project, it may be worth looking at other options and we can advise.