Volvo Ocean Race - Images of the construction timeline of the new 65s

Team Dongfeng’s new Volvo Ocean 65 is transported from Green Marine to Southampton docks for structural test.

Volvo Ocean Race 2014-15 gets underway from Alicante, Spain in October. Almost two years after making the announcement of the switch to one-design back in June 2012, two Volvo Ocean 65s are out of the shed and one has already been training for over a month.


The Volvo Ocean Race picture desk has prepared a series of images to illustrate the construction timeline of the new boat to compete in the next two editions of the 40,000nm Round the world Race.

Work starts with a full size model of the boat built out of wood. This interior mock-up is used to fit the different components and systems inside the boat and finalise design details. - Volvo Ocean Race 2014-15

First the hull is built at Persico in Italy. A highly accurate milling machine carves out the plug from a big block of polystyrene. Then the hull mould is built on that plug. - Volvo Ocean Race 2014-15
Rick Deppe

Boat builders laminate carbon to create the outside layer of the hull thanks to a 12.5mm-thick mould. Once completed, the hull is cooked at 90° C for about seven hours. A sudden change in temperature could damage the hull. - Volvo Ocean Race 2014-15
Mark Somerville/Persico Marine

Once the lamination is complete, the hull is transported from Bergamo in Italy to Southampton in England to be assembled with the deck at the Green Marine boatyard. - Volvo Ocean Race 2014-15

Meanwhile, the deck is built at Multiplast in Vannes, France. Also made out of carbon fibre, it too is transported to Green Marine to be assembled with the hull. - Volvo Ocean Race 2014-15
Agathe Armand /Volvo Ocean Race

In England, boat builders start working on the bulkheads, key components of the internal structure of the boat. In an effort to make the new Volvo Ocean 65 stronger and safer, it has eight bulkheads – that’s around double the average number in the Volvo Open 70 on the previous race. - Volvo Ocean Race 2014-15
Pedro Freitas /Volvo Ocean Race

Once the bulkheads are fixed, the hull and the deck are assembled. This picture shows the two components finally attached. - Volvo Ocean Race 2014-15
Pedro Freitas /Volvo Ocean Race

Boat builders are finalising details inside the boat – that’s the fit-out phase. Work inside the boat takes place in a very small and dark space. - Volvo Ocean Race 2014-15
Pedro Freitas /Volvo Ocean Race

: It takes 120 people working directly on the boat to build a Volvo Ocean 65 in seven months. A total of 36,000 man hours are required. - Volvo Ocean Race 2014-15
Pedro Freitas /Volvo Ocean Race

Inside the Volvo Ocean 65. On one side are the bunks where the sailors will sleep in four-hour watches. - Volvo Ocean Race 2014-15

View from the companionway. The galley (or kitchen) sits in the middle and two gas bottles provide fuel to heat the water to prepare the freeze-dried food. - Volvo Ocean Race 2014-15

The boat is now fully assembled and all systems are installed – it’s time to paint in to the team’s colours. - Volvo Ocean Race 2014-15