INTRODUCTION TO BAVARIA YACHTS

BAVARIA YACHTS                                                                                              2009

General Information

AN INTRODUCTION TO BAVARIA SAILBOATS by Bill Hooper

Dear Sailing Enthusiast:

Since 1979 the name of Bavaria Yachts has been synonymous for sailing and motor yachts of outstanding value and quality. Now 30 years later Bavaria still incorporates the best of German craftsmanship and state of the art methodology. 

Three decades ago they built their first boat, the “707”  (pictured to the left) and now they’ve moved into the forefront of production boat building and are the 2^nd largest builder in the world. Their yachts stand out for their solid and lasting value.

Innovation, modern manufacturing methods, computer-aided manufacturing processes and highly skilled craftsman all enable Bavaria Yachts to be produced with an eye toward cost effectiveness without skimping on quality. 

Bavaria sailboats are ruggedly-built vessels built to exacting standards via a sophisticated automated method of manufacturing which keeps production costs to a minimum. This translates to an outstanding value for the boat owner.

Bavaria Yachts are well represented and are presently shipped world wide to other destinations such as the United States, Caribbean, Japan and Australia. The dealer network is world-wide and we are happy to be Bavaria dealers because they represent quality at an unexpectedly reasonable price.

In the past several years we received lots of positive feedback about Bavaria Yachts from local sailors attending larger shows elsewhere.  The boats were gorgeous below and their exterior designs stunning. Their standard list of features are many. They have a great deal of appeal and when compared in price with other products in the marketplace, people were amazed and wondered how this could be accomplished.

Bavaria recently upgraded their manufacturing facility in Giebelstadt, Germany to a huge complex (600,00 sq ft) that is so efficient and clean that you can practically eat off of the floor and the need for a large staff of boat builders is not necessary because of their automation and robotics used in production. Now, as of this updated writing in June of ’08, Bavaria is currently initiating some rather extensive plant expansion again as well as the introduction of new models.

   Bavaria incorporates 12 CNC Fraise machine (pictured left) which is a large cutting and drilling tool for large sections of ship-building materials that is controlled by intelligent computer software that is used for decks, bulkheads and interior furniture. The system automatically cuts and bores components, including entire decks (hatch cutouts, etc.) which is an important pre-condition for later assembly. This is done in a fraction of time in comparison to manpower. 

I have visited several large boat manufacturers since I have been in the sailboat business (early-70’s) and most facilities are set up with bays dedicated to runs of the same size boat. At Bavaria, they can have a 50 foot vessel being built along side a 30 foot vessel efficiently as seen to the lower left.  

All parts such as doors and other components are identical.

There are not large numbers of boat builder employees running around the yacht, boring holes with drills, cutting out hatches with jig saws as seen at most manufacturing facilities.

At Bavaria this produces high-quality work which represents about 65% of the boat building process which translates into quality control and savings which are passed over to the customer.

All employees are divided into groups to work on different components and each staff member is trained to work on all facets for the production schedule so that they are capable of taking over another person’s job due to absence in case of sickness or vacation, etc.  This all contributes to quality control.

Hulls and decks are laminated within the same facility and care is taken to assure uniform tolerances within the entire structure. Lamination rooms are air conditioned with a permanent humidity and temperature control to assure a consistent lamination process. Below the waterline the hull is constructed of solid fiberglass with controlled volumes of material and gelcoat that ensures water integrity and protects against osmosis. Above the waterline and in the deck a sandwich laminate using PUR-foam core is used. The core material provides insulation and reinforcement and keeps the entire vessel lighter

without compromise to strength for added sailing ability. A multiaxial woven roving is also used in the laminate as well to minimize collision damages and endangered areas of the bow are protected by an aramid fabric with impact strength.  You can look through the entire assembled yacht to see where all components are located and how the boat is constructed, which is important for future inspections. There are no systems or components that are hidden where you cannot see any deterioration or failure over time. I cannot tell you how many vessels have chain plates or partial bulkheads that rot out and cannot be detected because they have no access for inspection.

Interior components are pre-produced to exact specifications by the CNC automated system. Millings, drillings and grooves are carried out precisely. All wooden components are given a uniform multi-layered 2-part varnish and additional UV protection. These modules are designed for easy and efficient production and so that the entire hull to deck joint is accessible from every position.

All Bavaria Yachts leave the yard only after a detailed final quality control. The innovation, modern manufacturing methods, computer-aided manufacturing processes and the highly skilled craftsmen all enable Bavaria boats to be built with a high degree of quality, yet comparatively inexpensively.   

Selden’ Spars provide the spar and rig components for all Bavaria Yachts. Selden’ is a product that Hooper’s Yachts has represented for several years. To be a Selden/Furlex dealer one must go through their rigid training, which we have completed. Selden, now over 25 years old, has become one of the world’s foremost manufactures of masts to boats as big as 30 tons.

Their in-mast furling incorporates an external line drive system which ensures that there will be no chance of the furling line getting over-rides or inaccessible tangles in the event of a line failure. This, in conjunction with a winch handle aperture in the drive, allows for manual override of the system ensuring that the mainsail can always be unfurled and lowered. Having dealt with Furlex jib furling systems for many years, and also now having experience installing their “In mast” furling spars in an aftermarket or replacement situation as well as during commissioning of new boats, I know their quality control is unsurpassed. You can compare some of the competition’s rigs and see that the same section is used over a range of sizes of their boats. A Selden rig is custom fit based on vessel details which include dimensional factors to determine righting moments so that spar sections are individually selected for each Bavaria vessel. And each Bavaria Yacht’s mast has a dedicated serial number for future reference and for part ordering. They are quite on top of their game. When you order your new Bavaria, you have the option of choosing either an in mast furling mainsail or a conventional mainsail with either full-battens or standard battens. In addition all Bavarias are equipped with the Selden Rigid Vang.

Volvo Penta saildrives are the propulsion used in Bavaria sailboats. Volvo Penta invented the sail drive now popular with other brands. Because Volvo Penta has the most experience in drive design and production, you benefit from expertise with the best materials and manufacturing techniques. In addition, Volvo Penta produces their own propellers. They are a complete propulsion system supplier with extensive in-house prop design expertise developed from years of sail drive and out drive design and manufacturing. The standard prop on a stock boat is larger and deeper than shaft props allowing more power and efficiency.

Sail drive propulsion are also smoother and quieter than shaft installations and do not require a shaft log, strut, stuffing box or cutlass bearing. Sail drive installations are more efficient under power. Their horizontal shaft directs all power thrust to push the boat forward, not down at an angle like most shaft installations. The gear reduction is the same in forward or reverse so there is equal loading in either direction and prop walk is minimal. Sail drives have no alignment issues, no leaking stuffing boxes and they have less drag. In addition they take up less room in the boat.   

Bavaria Yachts has been in business since 1978. They have produced up to 4,000 yachts a year.

Last year, Bavaria sold 3,500 boats. Past clients include Formula One supremo Mike Gascoyne. The technical chief of Force India — billionaire Vijay Mallya’s racing team — arrived for last year’s Monaco grand prix in a Bavaria boat, having sailed from Barcelona with his wife. They are everywhere in Europe and are in larger concentrations along the two coasts of the U.S., in the south as well as growing in the Great Lakes area and now the Midwest.  A few years back we sold a Bavaria 36 to a sailor who just returned from a trip to Norway. His comment, upon return, was, “Bavarias are all over the place”.