Sportsman Boats launches *The Sportsman Insider*, a new video series showcasing real-time updates on prototype builds. The first episode dives into the hull and stringer construction of the all-new Open 402, the largest and most advanced Sportsman to date.
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•The Sportsman Insider delivers real time updates on prototyping and production milestones
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•The Open 402 showcases Sportsman 3.0 design with a hull engineered for strength and offshore performance using vacuum infusion
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•The manufacturing approach emphasizes precision and efficiency with the hull built quickly and a robust stringer system adding long term durability
Sportsman Boats has launched a brand-new series called The Sportsman Insider, designed to give an inside look at the prototyping and progress of our latest models. Unlike Behind the Glass, which focuses on the fine details of boat building, The Sportsman Insider brings real-time updates as our boats move through critical stages of production.
The very first installment features the all-new Open 402—the most ambitious center console we’ve ever built. As the flagship of the Open Series and a defining model under the new Sportsman 3.0 design language, the 402 sets the tone for the next generation of Sportsman Boats.
Building the Hull
Every great boat begins with a strong foundation, and for the Open 402 that starts with the hull. Using our proprietary SportTech® design, the hull is engineered for strength, comfort, and efficiency. Built to run confidently in rough seas, it promises the smoothest ride ever offered on a Sportsman.
The process begins with a precision-applied gelcoat, creating the glossy, durable finish our customers recognize. Operators then add a protective skin coat, followed by layers of chopped fiberglass and resin to ensure consistency and strength. From there, laminators roll each section to remove air pockets and secure adhesion.
Next comes infusion prep. Dry fiberglass and CNC-cut core materials are laid into the mold like a puzzle, first with the hull sides, then flipped to complete the bottom. Peel ply and resin flow lines are added to guide resin distribution. A high-heat bag is sealed over the mold and vacuum infusion begins, pulling resin evenly across the part. This technique ensures the hull is both lightweight and durable, ready to perform under demanding offshore conditions.
From skin coat to fully infused, the team can complete a hull in about 16 working hours—a true showcase of training, precision, and efficiency.
The Stringer System
With the hull complete, attention shifts to the stringer, another fully infused component that provides the backbone of the boat. Unlike the hull, only visible sections such as the bilge, fish boxes, and Seakeeper pod receive a gelcoat finish. The rest is built using dry fiberglass and core before undergoing the same infusion process. Once complete, the stringer drops directly into the hull, adding strength, housing systems, and ensuring long-term durability.
What’s Next
This first look at the Open 402 marks just the beginning of the Sportsman Insider series. Upcoming updates will cover rigging, capping, and more as this groundbreaking model comes to life.
Stay tuned as we continue documenting the progress of the Open 402, a boat that not only raises the bar for Sportsman Boats but also redefines what’s possible in the world of center consoles.