Courtesy Geoff Van Gorkom A new performance cruiser from Van Gorkom Yacht Design anticipates a revival of sailboat construction in North America.
The “Made in the U.S.A.” badge has been a stamp of quality in the global boatbuilding industry. Unfortunately, in response to economic pressure over the past 30 years, many U.S. manufacturing companies have closed their doors or relocated their construction operations abroad in a bid to remain competitive. So, it should come as no surprise to anyone in the recreational marine sector that sailboat production in the United States is at an all-time low. Meanwhile, most new production and semi-production sailboats being sold in the U.S. are being built offshore in Europe and Asia.
Courtesy NMMA I’m heartened by some recent signs that this trend may be heading in the other direction, providing a real opportunity to inject some life back into our industry. For example, material costs and labor rates for many of the dominant European and Asian manufacturers have steadily increased over the last several years, not to mention the U.S. tariffs recently imposed in almost all trading nations, should they remain in place. In the face of that trend, U.S. boatbuilders, powered by a skilled domestic workforce, have started to look more affordable and a lot more convenient for the North American market. I’ve seen real interest out there among buyers, and that translates to design commissions in my office.
A case in point: I recently had a custom cruising sailboat project come through the office that unfortunately didn’t get to the build stage with the initiating client. However, it alerted me to the fact that there’s a viable market for expedition-focused sailboats out there that’s new to U.S. builders. It’s a niche sector that French and Dutch boatbuilders, such as Alubat and KM Yachts, have been successfully capitalizing on for years, to the point that these manufacturers currently have orders extending out to 2028.
While the commission vaporized, I couldn’t ignore the preliminary design study for the custom pilothouse cutter. It became the genesis for the Van Gorkom Yacht Design EXP44. Conceived of for the cruising sailor who wants to explore some off-the-grid corners of the world, it’s a 44-footer (13.4m) with blue-water capabilities. The base hull and deck arrangement with a quasi-customizable interior makes this boat the ideal vehicle for an established U.S.-based boatbuilder, or a startup enterprise, to produce a quality product on a semi-production basis. To be clear, this opportunity is not about repeating the pattern of cutting corners to yield an inexpensive production model—the mistakes that drove so much business offshore. To establish a credible brand, this cruising yacht will need to be built to a high standard and be tough enough to safely withstand the rigors of the open ocean.
As with all design projects, I had to make compromises when balancing form and function, particularly when considering the mission statement of an “expedition” yacht. Aluminum was chosen as the base building material, not only for its robust properties, but for its ease of construction. I’ve specified that all structural elements will be fabricated in 5086 aluminum for plating and 6061 for extrusions. The “Erector Set” type of assembly, made up of precise waterjet cut parts, makes for cost-effective boat building by guaranteeing repeatability and reducing construction time. The hull, deck, and internal structures are all engineered to ABS and ISO standards.
Hull & Appendages
The chined hullform and slightly reversed sheer of the EXP44 is a development of VGYD’s second generation go-fast boats. The hull designs of our Mini 6.5 2G and the 2XS-30 incorporate the latest proven trends in hydrodynamic efficiency. These models carry a generous amount of reserve buoyancy, a moderate prismatic, and there’s a concerted effort to reduce the pitch moment. This philosophy, along with an additional emphasis on maximizing the waterline and interior volume, will result in a sea-kindly and comfortable yacht that I predict will be quick and efficient through the water.
Courtesy Geoff Van Gorkom The EXP44 carries some of the hull shape and performance DNA from Van Gorkom’s recent competitive offshore models, the Mini 6.5 2G (left) and 2xS-30.
The EXP44 has a minimum shoal draft of only 4 feet (1.22m), allowing it to comfortably anchor in most of the planet’s cruising grounds. However, sailing performance has not been neglected as is common among some of its expedition yacht counterparts. The boat is fitted with a high aspect ratio, hydraulically controlled, solid steel, rotating centerboard arrangement that projects from a ventral keel fin to a maximum draft of 9′10” (3.0m).
Courtesy Geoff Van Gorkom The complex hydraulically controlled, rotating steel centerboard is an instance of Van Gorkom choosing performance over the practicality of simple bilge keels.
To optimize the vessel’s righting moment, the primary fixed ballast will be made up of preformed lead ingots sealed into the fin. I considered bilge keels for this design, but the emphasis on performance outweighed the practicality of beaching the boat. This issue was resolved via the twin aluminum skeg rudders that complete the shallow draft appendage package. The integral structure of the skegs, along with the keel fin, form a tripod allowing the boat to sit level on the hard. The skegs also provide damage protection for the rudder blades. The option of composite spade rudders is available for the cruiser looking for a little more performance.
Rig
The sail plan and rig configuration of the EXP44 are optimized to balance performance and user friendliness. In terms of raw performance, the EXP44 has a Dspl/LWL ratio of 135, a SA/Dspl ratio of 21.4, and a Dellenbaugh Angle of 12. In short, the boat will not disappoint under sail, and its motion should be neither too stiff nor too tender. Controlling the sail plan will be relatively easy in most wind conditions as it is broken down into three working sails—a 95% jib, a staysail, and a main. The mainsheet leads back through the boom, then down below to a Harken captive reel winch, giving the helmsperson push-button control of mainsail trim. The jib and staysail have Harken roller-furling systems for user-friendly control of the headsails. The asymmetric gennaker deploys from the bowsprit on a roller furler for easy sets and douses. All control lines lead back to the cockpit, ensuring the crew rarely need to go forward in heavy conditions. The rig is centered around a deck-stepped aluminum mast with swept-back upper and lower spreaders, and an alloy boom (carbon fiber spars are an option). The bridled backstay is controlled with a hydraulic, single-acting ram.
Courtesy Geoff Van Gorkom The EXP44 rig is a compromise between high performance and manageability for a small crew in challenging sailing conditions.
The contemporary styled raised salon and pilothouse not only complement the aesthetics of the hull and rig design, they also allow for an unobstructed view of the outside world. The superstructure interacts seamlessly with the partially enclosed working cockpit, which provides heavy-weather protection for the crew, yet is expansive enough for entertaining or solitary relaxation. The cockpit opens to twin helm stations aft and a walk-through to the transom steps that allows easy boarding access and doubles as a swim platform. The radar arch accommodates an array of antennas, and its integrated lifting arm allows it to serve double duty as a dinghy davit.
Courtesy Geoff Van Gorkom A practical deck layout marries an uncluttered working foredeck with a sheltered cockpit housing twin helm stations.
Accommodations
Within physical limits, the voluminous interior can be customized to suit different use profiles as envisaged by the range of owners the EXP44 is likely to attract. In the standard version, there’s a roomy stateroom forward and one to starboard and aft. There are two heads with showers, the fully equipped galley is to the port side of the saloon, and there’s a raised dining area to starboard with panoramic views. The table and bench seats can be also converted to a spacious double bunk. The navigator sits forward of the dining area with clear sightlines to the course ahead. There’s plenty of stowage, as well as a day bunk on the port side forward of the saloon. This area could also be for a washer/dryer unit and storage, or perhaps a work bench area. With generous standing headroom throughout the boat, there are many possible interior layouts.
Courtesy Geoff Van Gorkom EXP44 accommodations plan.
Drivetrain & Systems
The EXP44 is powered by a Yanmar 80hp diesel engine through a sail drive, giving the boat a cruising speed of 8+ knots. There is good access to the engine, port, and starboard, accessed by removing interior paneling. There’s also a soft patch in the cockpit sole in case the engine needs to be pulled. The two 95-gallon (360 l) fuel tanks and a 10-gallon (37.8 l) day tank give the boat a motoring range of approximately 600 miles at cruising RPMs.
The Sail Drive “C” configuration positions the lower unit up behind the keel where it is naturally protected from impact with flotsam and jetsam. For maneuvering in tight places, the boat is fitted with a retractable bow thruster.
House electricity demands can be met by the 9.5kw diesel generator, with supplementary voltage coming from a solar panel array mounted on top of the pilot house. There is a 500-Ah lithium-iron-phosphate battery bank with a backup AGM battery. Double-pole switching throughout the boat will eliminate the potential for stray current—an important consideration on an aluminum boat. The boat will carry 120 gallons (454.2l) of potable water, although lesser tankage backed up by a water maker is an option.
Courtesy Geoff Van Gorkom EXP44 Particulars
LOA (hull): 13.41 m (44′ 0″)
LWL: 13.27 m (43′ 6″)
Max Beam: 4.03 m (13′ 3″)
Draft (up): 1.22 m (4′)
Draft (dn): 3.00 m (9′ 10″)
DSPL (sailing): 11,340 kgs (25,000 lbs)
Ballast: 4,082 kgs (9,000 lbs)
SA (upwind): 106 m2 (1143 ft2)
SA (downwind): 163 m2 (1753 ft2)
About the Author: Geoff Van Gorkom is a degreed naval architect/marine engineer and the principal designer at Van Gorkom Yacht Design (Portsmouth, Rhode Island), which he founded in 1994. He has extensive experience designing sailing yachts, from America’s Cup boats and IOR Maxis to the VG-Mount Gay 30. He has also designed tug-and-barge structures, conducted vibration analysis of marine powerplants, and engineered rigs and rigging components.
