Custom Seal for Luxury Yacht in the USA

13th January, 2026

The client initially reached out to our team at Aquaseal Rubber after seeing a previous post about us sorting out a seal problem in France for an existing customer. They were aware we made rubber seals for doors on other yachts and asked if we could go and visit the vessel while in dock in the USA, to assess the doors and yacht seals.

However, we found that working directly with the on-board engineering team through online communication channels was successful, and we knew what they were trying to achieve without getting anyone to fly over to assess the issue on board. The yacht had several access doors and the current seals weren’t working, and the issue was that the doors were twisted due to being so large and made from fibreglass reinforcement.

Work began with the client to create their bespoke rubber seals for the yacht. Due to the harsh environment that the seals would operate in, with constant contact with seawater and direct sunlight, and the fact that the client requested white seal, we decided expanded silicone would be best for this project. After weeks of communications, we asked the client to take measurements of the channel that the seal sits in, and we then discussed both the size and compression requirements of the seal.

Before starting the manufacturing process of the seals, we gave the client expert advice on how to use a plasticine method of seal measurement so they could confidently use the plasticine and know where to place the blocks. The client then provided us with an average size of the seal required, and the team began designing a seal that would accommodate the variation of thickness around the door. The seal had to specifically fit so that it was compressed all the way around the hatch, ensuring that there would be no water ingress. The seal couldn’t be too high or too hard as it had to be flexible enough to compress more in certain places and less in other places.

The next step in the process was manufacturing a sample seal measuring two metres long to test fit on the hatches, and once this was tested the client ordered the full volume of seals required for all the hatches.

The client was extremely impressed with the work by Aquaseal Rubber.

Chief Officer Nick Touhey said, “the knowledge and advice passed along has been exceptional, the seals have been fitted without any issue and are working fantastically, fully passed by the insurance company and I would without doubt pass on Aquaseal’s name and praise them highly after the help and advice we received with our hatch sealing issues.”

Key points in the design we had to take into consideration:

• The harsh environment that the seals would be exposed to (sea water, direct sunlight)
• Large variation of thickness around the door
• The seal had to compress more in some places and less in others
• The seal had to be flexible
• The client requested white seals

This project was a great success for Aquaseal Rubber and we are happy that the client is satisfied with our work.

If you have any rubber needs for your project, or if you are looking for support on maintaining and extending the lifespan of your yacht’s watertight seals, our team at Aquaseal Rubber can help. We can design, manufacture, supply or install luxury yacht door seals and other yacht seals made from rubber materials to suit your bespoke needs. Contact us to see discuss your bespoke rubber requirements.