Konjo master builders at Ara and Bira work hull-first, often without formal blueprints: the shell is shaped from inherited proportion rules, planks are edge-fastened to each other with hardwood dowels, and only then are frames fitted inside – the reverse of Western practice, where the frames come first and the planking is hung on them.
Stage by stage
Every wooden boat on this coast passes through the same broad sequence, whatever its final fit-out.
- Timber selection and seasoning. Bitti, ironwood and teak chosen and dried before anything is cut.
- Keel-laying and the first ceremony. The keel is laid on an auspicious day, with ritual measures embedded in the work.
- Planking hull-first and dowelling. Planks are shaped by eye and edge-joined with pasak – wooden dowels – into a fair shell.
- Framing, decking and superstructure. Frames are fitted inside the finished shell, then the deck and house go up.
- Caulking, systems and rig. Seams are payed, engines and tankage installed, and the rig or motor-sailer set-up completed.
- Launch and sea trials. The hull is hauled to the water on timber rollers, then trialled before handover.
How long it takes
Reported build windows vary with size and fit-out. As a working guide: a 15-20 m hull takes about 10-14 months, a 20-30 m hull about 14-20 months, and a 30-45+ m custom yacht 20-24+ months. A plain 30 m hull with a steady crew can be done in about 9-12 months of hull work; the interior is what stretches the calendar. Treat these as reported ranges, not a promise – timber and weather move them.
What drives the schedule
- Timber availability and moisture content – green wood cannot be rushed.
- Crew size and whether the yard is running parallel builds.
- Owner change-orders and how promptly stage payments clear.
- Weather and the launch window, which is chosen around tides.
Milestones owners should witness
- Keel-laying – the start, and a ceremony.
- Planking and the dowel schedule complete – the hull is now fair and closed.
- Launch, sea trial and handover – the payoff.
Reserve a build slot
Slot availability changes with the yards’ order books. Ask the desk on WhatsApp for current keel-laying windows before you plan a season, and read the timber and craft page for what goes into the hull and the cost guide for what it means for the budget. The heritage behind the method is set out in the Ara and Bira heritage page.
Ask about keel-laying windows or email sales@komodoluxury.com
Frequently asked questions
Do Bira builders really use no blueprints?
Traditional Konjo builds proceed from memorised proportion rules rather than drawings. Modern charter yachts often add naval-architecture drawings on top, but hull shaping remains the master builder’s craft.
Why is the hull built before the frames?
Planks are edge-dowelled to each other to form the shell first; frames are then inserted to stiffen it. The sequence preserves the fair hull shape held in the master’s memory.
How long does a 30-metre boat take?
A straightforward 30 m hull is reported at about 9-12 months of hull work; fitted out as a charter yacht the full project typically runs 14-20 months or more depending on interior specification.
Can I visit my boat during the build?
Yes. Owners are welcome at agreed inspection points; for continuous on-site owner representation the group offers a separate supervision service through the shipyard channel.
Does work stop in the rainy season?
Work continues most of the year; heavy rain slows caulking, finishing and launches more than framing. Launch dates are chosen around tides and weather.