FACTORY TOUR

Malibu is the first and only ski boat manufacturer to own and operate multiple manufacturing facilities. East and West Coast facilities enable us to deliver our products nationwide with a significant freight advantage to our dealers and customers. The three factories also provide more resources for new products and allow us greater distribution capabilities throughout the world, which means increased sales four our dealers and better service for our customers.

Mold Prep

The initial stage of the boat building process is the most important stage to assure boats of the highest quality and performance. If attention to detail is not observed each step of the way, the result is a boat that can be aesthetically or structurally flawed. That is why Malibu uses a technologically advanced process to insure the quality and beauty in each and every Malibu. Our molds are constructed of dimensionally stable resins and ceramics and supported with steel frames to ensure the highest possible consistency. The surface of the mold is coated with a specially blended Polycor conductive gelcoat designed to withstand the high temperatures experienced during the lamination process. Once cured, the surface is meticulously buffed to a high gloss shine with specially formulated buffing compounds. Our flawless exterior finish is achieved through careful mold preparation. An entire day is spent meticulously cleaning the mold, then hand applying four coats of wax before every mold use so that every Malibu boat maintains its rich luster.

Gelcoat

Once the mold has been prepared, the first step in producing a Malibu is a 10-step in-the-mold gel coat process. Each boat is painted with a resin-based paint called gel coat, which creates a chemical cross-link to fiberglass — permanently bonding the gel coat to the boat. Malibu gel coaters have over 20 years of experience and are some of the most respected artists in the marine industry. Tapelines are applied by hand and hundreds of different color combinations are used to create each unique Malibu. Malibu uses specially formulated materials applied in a temperature controlled environment. Every custom color is specially blended to create the most beautiful and durable boats on the water. Even though ISO Resins are more expensive, they are best in terms of chemical and moisture retention, impact resistance, toughness and flexibility. Malibu finishes their industry leading process by applying a final Armor Guard vinyl ester black barrier coat to enhance colors and resist print through from the hand laid fiberglass.

Lamination

Malibu’s lamination process is more than hand laying fiberglass into a mold, it is seamlessly creating a structure that becomes unitized for the strongest & quietest operation on the water. From the first step of implementing a cosmetic skin coat with continuous roving to the multiple layers of double bias, 24 oz. roving and quadraxil hand laid fiberglass our lamination schedule is comprehensive and thorough. Malibu introduced the FibECS system and received a U.S. Patent in 1993 and it has performed flawlessly since its inception, resulting in zero failures in over 40,000 boats. FibECS is the strongest and quietest engine chassis system available in a boat today. The engine is through-bolted to Malibu’s patented Fiberglass Engine Chassis System (FibECS) which distributes the load over eight attachment points rather then four, resulting in a more stable and quieter operation. Unlike some of our competitors who still use a traditional plywood floor or thinly laid fiberglass, Malibu utilizes a Space Age Fiberglass Floor System. Space Age only uses E-Glass mat reinforcement with its Thermo-Lite Board® to ensure consistent quality & greater strength to weight ratio than traditional fiberglass and a virtually indestructible foundation in our boats, creating the most substantial power plant foundation in the industry. Floatation foam will be injected on the starboard and port side of the floor. This ensures level flotation, noise and vibration dampening.

Assembly

The completed Hull and Deck will now be sent into the grinding booth. The edges of the hull and deck will be grinded to remove all excess fiberglass and gel-coat left from the molds. This is done to create a smooth-edge finish of both items. The Hull and Deck portions will now be prepped for numerous items that will be installed during this day of production to the exterior and interior of the Hull and Deck. The exterior will have many items that will be precisely marked and then drilled and mounted. Items such as the rub-rail molding and insert, pull-up cleats, fuel fills, bow and stern navigation light bases, docking lights, tow eyes, fuel tank vent, and the transom grab bar will be items that will be mounted to the exterior of the Hull and Deck.

The interior will have items such as the, wire harnesses, interior lights, and drain plugs that will be installed. Portions of the stringer system and deck transom will be drilled for use of the active air induction and blower ventilation system. The transom will also be drilled for the installation of the port and starboard engine exhaust ports and if equipped the Hydrophonic Dampening Box will also be prepped for production.

R&R Carpet which has been cut out utilizing CNC technology will be installed over the floor using an industrial strength glue. The carpet will fit specifically to each individual Malibu Model to allow for complete and uniformed coverage.

Once the prepping and mounting of the internal and external items of both the deck and hull have been completed the joining of the deck and hull will begin. The Deck will be lifted with a hoist and lowered down on top of the Hull which has been prepped with Weld-On. The fit that is created between the two is called a shoe-box fit. A shoe box fit, means the deck will fit over the hull like a shoe box lid. Once the deck has been lowered onto the hull and put in place, 3/8” stainless screws will be used to hold the deck in place while the Weld-On Fusion Adhesive joins the two structural components at a molecular level together. The four composite structural components to include the, Hull, Deck, Floor and Stringer System have now been joined together at a molecular level to form one complete composite structure. Once joined together, personnel will begin to complete the assembly of the Hull & Deck, fiberglass tabs will be used to join all molded seat bases, bulk-heads and walk-thru areas of the boat to the floor and hull, increasing the structural integrity of the boat. The final step in assembly will be to install Rub-Rail Molding and Insert around the entire circumference of the boat. The protective molding will be attached to the boat using aluminum rivets. The stainless or rubber insert will then be installed inside the molding to finish the look off and complete the day of production. The molding will visually eliminate the seam line of the Hull and Deck from one another and also provide a protective guard from unwanted damage to your Malibu.

Rigging

The shell of the boat is now in the hands of the experienced crew who specialize in electronic and mechanical functioning components which will be mounted to the internal and external portions of the boat, these items will include: engine power-plants, dash systems, exhaust systems, fuel systems, ballast systems, precision underwater gear, stereos and a wide variety of electronic/mechanical accessories and options.

The Rigging Department will construct and prep the dash system for installation. Each dash will be constructed based off a work order sheet which will include all the standard features and optional features for a particular Malibu model. The engines, fuel tanks, and ballast tanks (if equipped) will also be prepped before they are installed. The Rigging Department will now take the boat and flip it upside down. This is done to install all of the underwater gear of the boat to include the rudder assembly, strut, prop-shaft, and tracking fins. Every item is precisely measured and mounted to hull of the boat, all of which will contribute to the performance of the award winning hull designs. Once the boats underwater gear is mounted, the boat will now be turned back over and the installation of the interior systems will begin. Every electronic and mechanical system will be installed individually and will ultimately tie in to each other once all of the separate systems have been installed. The dash system containing all of the boats standard and accessory switch functions will be mounted and wired to the main wire harness of the boat which will include the standard cruise control system, dash monitoring system, ignition control system, ballast monitoring system (if equipped), stereo controls, interior and exterior light controls, bilge and blower systems, and an endless amount of accessory options that may be equipped. The fuel and “ballast (if equipped) systems” will also be installed at this time. The fuel cell and ballast tanks are made of Linear Polyethylene plastic and will be mounted in place with all electronic connections being prepped to tie into the dash or main wire harness. The exhaust system will be the next system installed. This system includes the rear exhaust ports, exhaust hosing, mufflers, and Hydrophonic Dampening System (if equipped). Precision marked points will be measured and drilled for the exhaust ports which will then be mounted and attached to the exhaust hosing. The Marine Mufflers will now be attached and ready to be connected to the engine power-plant. An Indmar Marine Engine will now be raised and lowered onto the Fibecs-Stringer System. Once the engine has been put in place, the engine will be thru-bolted to the stringer system utilizing eight mounting points; this is done to disperse the weight and vibration over a greater area to allow for a quiet and smooth ride. The engine will now be tied into the dash, fuel, and exhaust systems along with all the other individual accessory systems.

Upholstery

In upholstery installation Malibu installs the most luxurious 38 oz. G&T upholstery the industry has to offer. The interior, does not fall short of Malibu’s impeccable name and comes complete with mildew resistance and U.V. protection. Tri-ply foams are used for the greatest durability and comfort providing years of worry free performance. You can feel the difference with softer foams supported with higher density foams for enduring comfort.

Lake Test

Malibu’s lake test department is overseen by highly trained technicians who understand the complexity of mechanical and electrical items in a Malibu. The first stage of lake test will include a dry-dock test, all electrical items will be tested to ensure they are operating correctly. Once dry-dock testing is completed the boat will be moved to the water, once on the water there is a 50 point quality assurance check list that will be completed. Every Malibu built is lake tested to ensure that the boats complete electronic and mechanical functions are operating and functioning harmoniously. All electronics are run through their paces for precision and function, the speedometer is calibrated with a radar gun, the Malibu Precision Pro Speed Control is activated and run through it’s settings, the Wedge is deployed and raised for proper functionality, the ballast system is filled and drained, electronic and mechanical systems all receive the final Malibu test to ensure every Malibu is completed and ready for shipment to your local Malibu dealer.

Detail

Once the boat has gone through all departments the boat is ready for a complete detail. Two persons will buff out the exterior of the deck and hull using bright lights to catch even the smallest imperfection, using high quality 3M polishing products to give the maximum quality finish to each Malibu Boat. After the boat is polished then they will go inside the boat to start cleaning the interior of the boat which includes upholstery lean backs, seat cushions, carpet, dash, and windshield. Once the boat is cleaned inside the quality control personnel will give a through cleaning inspection using there check off sheets, in the mean time the crew is hand waxing the exterior of the boat and the installation of decals will take place after they wax the boat. The Boat will be hand over to our quality control crew, they will give a written report of each boat to the departments evolved in the building process to insure quality consistency on a daily bases. Quality personnel is also in charge to make sure every part that will be shipped inside the boat is securely wrapped and correctly placed in before we completely shrink wrap the boat.