Malolo (ORC 50) came to us because their high-aspect foils did not meet the stringent quality standards required by a top-level racing team. The 4-meter foils needed a complete refurbishment, which involved stripping off the old gelcoat and recoating them precisely with Epoxy Graphite, following the exact original design specifications. To ensure accuracy, we reached out to the original designers to obtain detailed drawings and the corresponding NACA foil profiles. These were then meticulously converted into a 3D CAD file for better precision. Our trusted partners at Antigua Boatbuilding and Carpentary (ABC) used this digital file to CNC cut highly accurate templates. With these templates, we hand-shaped both foils to perfection, significantly enhancing their performance and fit.

Additionally, the boards were fitted with stainless steel pad eyes that had been causing damage to the daggerboard bearings during use. To resolve this issue, our skilled machinists crafted custom Delrin inserts featuring two different diameters—one specifically designed to fit the Dyneema lines and another to accommodate the dogbone hardware from A & A Rigging on the ends. These inserts were given a knurled finish, which ensured a much better grip inside the boards, preventing unwanted movement and providing peace of mind that they are secure.

Remarkably, just one week after Malolo received the upgraded boards back from us, they went on to win the multihull class at the prestigious 2025 RORC 600 race, demonstrating the tangible performance improvements achieved through our work.