WHY MALIBU

CHECK OUT OUR PROCESS FROM START TO FINISH ON HOW WE DO BOATS.

Despite Malibu Boats' industry leading stats, we gauge success by the level of satisfaction our boat owners enjoy. The Malibu Boats ownership experience is not about a list of awards, a bottom line or spreadsheet data; it's about
Malibu boat owners. We don't build boats the easy way, we build them the best way, and we don't go the extra mile in customer service because it's easy. We do it because it's the right thing to do and it directly benefits our customers.

Journalists have tried to write it. Other companies have tried to recreate it. Competitors have tried to downplay it. The culture of Malibu Boats is a unique and wonderful thing. It is an environment of family that lends itself to extreme amounts of fun and innovation. It's who we are.

Our Company

Located in South Eastern New South Wales in the City of Albury, Malibu Boats Pty Ltd, has been building premium quality American designed ski boats in Australia since 1995.

Driven by the desire to produce something of much higher quality and performance than was available at the time, Xavier West, approached Malibu in the USA about his ambitious dream. A meeting with Malibu President Robert Alkema was arranged in California and shortly thereafter, an agreement was reached to build their boats in Australia.

West wanted to build the best boats in the country, and provide water ski enthusiast with new, state of the art, modern designs that were of a much higher quality than anything else available. This has proven to be a master stroke as Malibu leads the industry with the creation of new and innovative designs like our V25 Wake and Cut Diamond hulls, our Frameless Vented Windscreen and the patented Power Wedge which have helped make Malibu Boats the most popular and desirable family tow boats in Australia today.


Follow Our Process

Malibu is the first and only ski boat manufacturer to own and operate multiple manufacturing facilities around the globe. East and West Coast facilities in the Unites States along with our state of the art facility in Albury, NSW Australia enable us to deliver our products worldwide with significant advantages for 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 for our dealers and better service for our customers.

 

Mold Preparation and Care 

Mold preparation is one of the more crucial stages of production; this sets the stage for the beautiful finish that Malibu is known for. A series of cleaning solutions are applied to the interior surface of the mold that eliminates all unnoticeable dust and debris. A second prepping agent that is also applied and removed by hand is used to revitalise the mold and reintroduce the shine and luster after each use. The final step in preparing a mold is the application of a mold release wax to the interior of the mold. This allows the newly constructed boat to be easily removed from the mold and will contribute to the high gloss gel coat finish when completed

 

Gel-coat Application 

Now it's time for Malibu's gel-coat artists to begin the application of hand applied tape lines onto the mold. Malibu uses 3M Fine- Line tapes to create razor sharp separation lines from one gel coat colour to the next. With the mold completely taped off it is ready for gel-coat application. Malibu uses a temperature regulated gel-coat spray booth to apply temperature regulated gel coats. Our gel-coats are the most advanced on the market and offer qualities such as, lower emissions, improved flexibility, and superior weather resistance to fading and chalking. The predetermined gel-coat thickness of .25 mils is constantly measured by Malibu's gel-coat sprayers. This measure allows for outstanding cosmetic qualities, but also is not too thick that it will lead to yellowing or gel-coat cracking. Malibu chooses the optimum thickness of .25 mils to ensure long lasting vibrant gel-coat finish.

 

Lamination

A combination of resin and fiberglass is the first application in the Lamination process and is referred to as the skin coat. This skin coat ensures that the consistency of fiberglass conforms to the lines, radii's, and groves of the mold and is applied by our lamination personnel. Next is the application of multiple layers in a variety of woven fiberglass sheets. These sheets will be hand laid in there predetermined positions and saturated with CCP Resins. This process is repeated until the desired thickness of the Hull, Deck, and Stringer System is achieved. It is during the lamination process that an acoustic layer is also added (MSST) which provides an exceptionally quiet ride. Other composite materials such as Klegecell, 3M Core-mat, Mantex Space Age Flooring and Polyethylene plastics will be utilised in different areas of lamination to ensure strength and act as backing support for any marine hardware.

 

 

FibECS - Fibreglass Engine Chassis System 

Malibu introduced this system and received a U.S. Patent in 1993. FibECS has performed flawlessly since its inception, resulting in zero failures in over 40,000 boats! FibECS is the backbone and strength of the boat due to it's "box section" design, but it is far from a traditional stringer system. This design allows us to directly through-bolt our engine to the Chassis system in turn eliminating the need for extra fastening systems, such as engine cradles or angle irons and also eliminates the old coach screw fasteners that just won't stay tight. By through bolting the engine mounts it allows for the load of the engine to be distributed throughout the entire system which eliminates engine thrust stress and vibration resulting in a smoother, quieter ride. The FibECS is a gel-coated fiberglass system that allows us to have a finish in the bilge just like the outside of the boat, and it also provides safe passage for wiring looms etc. Active Air Induction also increases the air flow to the engine through FibECS for greater acceleration, better fuel efficiency and better overall performance.

 

Mantex Space Age Flooring 

Malibu is always on the cutting edge of technology, and like our FibECS system, our flooring is industry leading as well. This Space Aged material is a marriage of Continuous Strand Fiberglass and Polyurethane Foam Board. This revolutionary product is stronger than traditional fiberglass flooring. Mantex only uses E-Glass mat reinforcement with its Thermo-Lite board to ensure consistent quality, which allows us as a manufacturer to continue to offer the Malibu Lifetime Structural Warranty. There are significant advantages over traditional building materials in nearly every area of comparison. Mantex flooring allows superior structural stability, but is far lighter than traditional fibreglass. It is non absorbent, resistant to rot and contamination, and accepts standard tooling and hardware. Unlike its fiberglass counter part, Mantex Space Age Flooring does not go through a lamination process so it does not give off any emissions and is environmentally friendly; however, it still maintains an adhesive ability to adhere to the Hull and FibECS. The one piece floor panel is built by joining several panels that are cut on our CNC machine which also cuts the foaming holes and various other cut outs to ensure each one is identical.

 

Weldon Fusion Chemical Bond - One piece Construction 

Our boats don't rely on mechanical fasteners to hold the major components together - (Hull, Deck, FibECS, floor) Malibu uses Weldon Fusion Adhesive that creates a weld at a molecular level to join the Hull, Deck, FibECS, and Space Age flooring together. Ultimately, when the production process is complete you have a boat that is literally ONE PIECE. There are no pop rivets or screws holding any major components together.

 

Hull, FibECS and Mantex Floor 

The joining of the FibECS to the hull is the first component of the boat to be fused together with Weld- On. The FibECS is pressed into the hull for a predetermined amount of time to cure and shortly there after the Mantex Space Age flooring is prepared with Weld-On and also pressed and fibre glassed into place. At this point the three major components have become ONE. Once these components have cured, the chambers beneath the floor are then filled with a 2 part expandable urethane foam through the pre cut 30mm holes. After the foam has cured the holes are then covered and permanently sealed with fiberglass tabs. Once this process is complete the hull is pulled from its mold and prepared for the marriage to the deck. During this process the deck of the boat is prepared and pulled from its mold to be attached to the Hull. All molds are then transferred back to the Mold-Prep department to start the process over again for the next proud Malibu owner.

 

Assembly

Next is the assembly and installation of wiring harnesses, interior lights, some marine hardware, exhaust ports, bilge ports, and carpet. Once all these components are installed the Deck is ready to be joined to the Hull using a "shoebox" fit; again using Weld-On Fusion Chemical Bonding All major components are now fused together and we have created ONE PIECE.

 

Rigging

Our rigging crew will now take the shell of the boat and install underwater gear, dash systems, fuel systems, ballast systems, stereos, exhaust systems, steering and most importantly the Indmar engine which will be through-bolted into the FibECS system all using stainless steel hardware. Once complete the department head will spend up to an hour checking off and filling out a comprehensive check off sheet. Once this paperwork is signed off the rigging department's duties are complete.

 

Interior Installation 

Following the rigging process will see the entire upholstery for each model installed. The upholstery which takes 3 production days to produce will now be installed and mounted. Upholstery items which are fixed all have pre-designed mounting hole patterns that are part of the design of the upholstery. Stainless steel hardware is used to through bolt the majority of these interior panels. The pre determined bolt patterns allow the installation of the upholstery precisely. Carpeted polyethylene seat bases will be installed which will allow the seat cushions to have a solid base on which to rest. Windshields, bow rails, interior grab handles, speakers and lights are a few additional items which will also be installed during this day of production.

 

Lake-Test 

Lake-test begins with a dry check and visual inspection of the entire boat which includes checking all electronics to ensure everything is working properly. The fuel system is pressurised and fully inspected along with the engine, ballast systems, underwater gear, steering and upholstery which are all visually inspected for function and proper installation. Now the fun part. The boat is launched and first inspected for leaks; the engine is then started and also checked for leaks and loose hoses etc. The boat is driven for a period of 20 minutes to an hour to ensure all mechanical and electrical items are functioning as designed. The Lake Test Crew will perform a 50 point check off sheet for each boat during this very important test. Additional items which will be checked include the calibration of the speedo with a GPS, the wedge system, ballast systems and Malibu's cruise control system. Steering wheel alignment and a high speed test are finally performed to ensure everything is as it should be. Once the physical lake test is completed the boats drain plug is removed and the final test of the automatic bilge pump is performed.

 

Final detail 

Once the boat test has been completed it is ready for final detail. The detail crew will begin this process by giving the entire boat an extensive cut and polish after which the decals and emblems will be fitted. Then the boat is again polished with several applications of wax and a final finishing wax. Next we will detail the balance of the boat which includes upholstery, carpet, dash, windshield, engine, bilge and all other mounted parts. We then utilise an extensive "final" check off list to achieve final detail and quality control. This inspection can often take more than an hour and regularly finds additional items that require an extra little polish or final adjustment. Once this check list is complete it is signed off and the paperwork is recorded and filed in archive. Now the boat is shrink wrapped, fitted to its specific trailer and freighted to your Malibu dealer.

 

Pre Delivery and Hand Over 

Upon arrival at your dealership the boat will be unwrapped and inspected again. A 32 point check list is completed and optional items such as bimini tops, boat covers and board racks are fitted, the boat and trailer are detailed again and registration numbers are fitted. The dealer will now contact the customer to let them know their new Malibu is ready to be taken to its new home. After a presentation of how to safely operate the boat and use its features correctly, a "final delivery document" is filled out to record the new owner's details and their understanding of the boats operation. The hand over is now complete and another proud Malibu owner is inducted into the Malibu family. End of Tour.