2009 Architectural Millwork/Overall Winner: Luxury On the High Seas

From the deck to the Captain’s quarters, exceptional woodworking is on display in this 5,000-square-foot yacht. Click here for a full gallery of Web Exclusive photos from the yacht.

Burger Boat Co.
Manitowoc, WI

Project: Ingot yacht

Year Established: 1863

# of Employees: 330

Shop Size: 50,000 woodworking; 500,000 ship building

This year’s Overall and Architectural Millwork category winner, Burger Boat Co., was without a doubt the judges’ favorite. For the first time in the 16 years of the Design Portfolio Awards competition, an entry received a perfect score.

Burger Boat, founded in 1863, builds custom luxury motor yachts up to 200 feet. The Ingot is approximately 153 feet. The custom interior features a “Neo” classical theme with raised panel Honduras mahogany and maple burl veneer accents throughout. There are 104 custom-built round Honduras mahogany pillars with maple burl inlaid veneers throughout the interior.

According to Mike Mitchell, director of interiors/senior design manager, “The lower accommodations include four large VIP staterooms with king- sized berths, incorporating unique joinery details like intricate foot boards, walls of raised panel mahogany and a blend of soft fabrics. Each VIP stateroom includes an en-suite bath with curved front vanities, heated floors and rare marbles, granites and onyx. Maple burl accents in drawer fronts, vanity fronts and columns complete the design.”

Natural finished anigre was used to construct the crew cabins, which include a large lounge area, separate laundry room and a walk-in refrigerator/freezer. Mitchell says that the captain’s stateroom is finished in raised panel mahogany.

The four-level interior of the luxury yacht also features a central staircase that has curved raised mahogany panels, a recessed solid mahogany railing and hand-forged wrought iron accents.

The yacht also has a salon and dining area, which feature two large coffered, back-lit white onyx ceiling panels, says Mitchell. “The single pedestal dining table as well as the coffee table/end table feature a matched crotch mahogany veneer face with inlaid ebony and mahogany accents around the perimeter.”

The dining table accommodates between six to 14 guests. A sliding mechanism allows for several leaf combinations.

The magnificent joinery for this project was completed in the company’s 50,000-square-foot woodworking shop (Burger’s total shipbuilding facility is 500,000 square feet). The raised panels in this project were created with a parametric program the company developed, utilizing its Busellato custom CNC router. “There were many challenges of curved and oval raised panels as well as compound curves in the main staircase in addition to built-in cabinetry and freestanding furniture,” Mitchells says. “Over 230 different moulding profiles were used throughout the project, with multiple compound mouldings requiring 3-D modeling using AutoCAD Inventor and five-axis shaping and machining.”


Other shop equipment includes: five-head Weinig moulder, two 5-foot by 10-foot VacuPress vacuum tables, two 17-foot by 17-foot by 17-foot Global Custom downdraft spray booths, two Kremlin spray systems, ML humidification system, Brandt edgebander, two Altendorf sliding table saws, CTD miter saw with Tiger Stop, Dodds dovetailer, eight Saw Stop table saws, Holz-Her vertical panel saw, Diehl straight-line rip saw, 24-inch SCM planer, 36-inch widebelt sander and a 24-inch Oliver planer dedicated to teak.

According to Mitchell, some of the most unusual characteristics of the project are the number of “curves, raised panels, columns and features, including all of the mouldings that follow all of the different shapes of the furniture.

“Specifically, the most challenging parts would be the curved raised panels in the main salon, the coffered ceiling overhead in the main salon, as well as the foot boards throughout (especially the one in the owner’s stateroom, which is curved). Another outstanding feature is the Teak Bar on the sun deck, as well as the four-story main staircase with curved raised panels and recessed handrail,” Mitchell says.

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