164′ Delta marine M/V Helios 3 gets new marine exhaust shrouds

Dolfab Metal Fabricators and Metcalf Marine Exhaust recently collaborated on 164′ Delta marine M/V Helios 3 to conduct much needed repairs to the exhaust system.

It was discovered the Helios 3 was suffering from leaks in the exhaust system. The exhaust system on a super yacht like this is truly an enormous, impressive thing. In order to be able to access it for diagnosis and conduct necessary repairs, we had to disassemble the system in stages: one whole day and a half was allocated to dismantling it and three days to put it back together.
Upon dismantling the system, the team from Metcalf Marine Exhaust was able to go in and remove the insulation within the exhaust. With the insulation gone, the Metcalf team then conducted several pressure tests in order to locate the leaks. Once the leaks were located, the Dolfab crew was able to go in and make the necessary repairs to the super yacht’s mufflers. After the repairs were complete, Metcalf reapplied insulation and then Dolfab reassembled the entire shroud system, repolishing all of the exterior components as needed to maintain yacht-quality #8 mirror finish. This stage took three days to complete.

The result is a like-new, polished marine exhaust that works and is befitting of the Helios 3. Truly a fantastic collaboration between marine repair professionals.


Dolfab Metal Fabricators is an expert in yacht repair, yacht refits, boat repairs, custom metal, Coast Guard certified custom fuel tank and fuel tank repair, T-Tops, RV repair, and an absolute expert professional with all metal fabrication. We are based out of Pompano Beach, Florida and service all of South Florida.

Waterjet custom metal window frames

We recently posted about some waterjet custom metal window frames that we at Dolfab were working on. We showed you the pieces, the custom table, and the waterjet.

But what was the thought process that went on behind the fabrication of these windows? What did we do different to improve on the previous set?  Jim Doll explains, in his very knowledgeable voice, how these window frames were made and what makes them unique.

Watch the video here:

Project highlight: 55′ Cheoy Lee Maraya’s new custom metal window frames


55′ Cheoy Lee sailboat Maraya is getting some new custom metal window frames by Dolfab Metal Fabricators

Creating custom metal window frames for a 55′ sailboat is a great testament to the ingenuity of the Dolfab team, and it gives us a chance to show you some of our equipment in action. These custom- made window frames require the use of our Waterjet cutter and a special router table that was created and assembled by our team specifically for this purpose.

The table allows for the router to be held in place while the window frames are turned around it, instead of the other way around (normally, the metal fabricator would turn the router around the piece being worked on). The pieces of metal being turned were too thin for the traditional application, so we came up with this solution:

This isn’t the first time we get creative with projects, and we know that it won’t be the last. Every metal fabrication project, yacht refit, and repair or custom project is unique, and we see new situations all the time. We draw from our collective experience in metal fabrication, which is quite extensive, to come up with innovative solutions to each new challenge.

We’re scheduled to complete this project over the next couple of weeks and will be posting updates to our Facebook page.

See Waterjet Cutter in action:

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