C Spar was set up in 1996 to supply composite tubing to the marine industry. The company has been owned and operated by Matthew Smith who has an extensive background of sailing, from dinghy classes, Whitbred Races and America,s Cups.
Mathew’s sailing and rigging background included these iconic New Zealand yachts.
In 2005 the C Spar range was taken over by Southern Spars and Matthew was involved in setting up their spar facility in Sri Lanka that produces carbon production spars for the 49er, Elliot 6M, VX sports boat, and the J70.
In 2012 Matthew has re-established C Spar as a standalone company operating out of Whangarei, NZ and broadened the company’s services to include big boat spar servicing and rigging.
C Spar, Spars and Rigging operates out of Unit 3, Dockland 5, 211 Port Road, Whangarei, New Zealand (PH 021 456185) and offers:
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Southern Spars have had a hand in creating Team New Zealand boats for the last six America’s Cup campaigns. Now they’re expanding their expertise into helping all kinds of athletes get that extra edge
They built the fastest America’s Cup yacht that New Zealand has ever sailed, and the wheels that transported Kiwi cyclists to six Olympic and world championship medals. Now Auckland mast-makers Southern Spars want to help more New Zealand athletes on to the winners’ podium, by taking their cutting-edge technology in ingenious new directions.
Maybe it will be Eliza McCartney’s vaulting pole; the New Zealand eight’s rowing oars; Luuka Jones’s slalom canoe; or even Liam Malone’s running blades. Southern Spars want to look at any sporting equipment that could be made from lightweight, strong and reliable carbon, and apply their design and construction expertise to it.
“Because of the way we think and design, we could really add value and give these athletes an edge,” says Southern Spars director Mark Hauser. “New Zealanders think a little differently from the rest of the world. That’s why we come up with boats with cyclists on them.”
For almost three decades, Southern Spars have been world leaders in designing and manufacturing masts and rigging for yachts around the world. Their history stretches back to Sir Peter Blake’s all-conquering round-the-world race yacht Steinlager II, in 1989, and Team New Zealand’s victorious Black Magic boats in 1995. When the America’s Cup was raced in Auckland in 2000 and 2003, the New Zealand company made all the masts in the fleet.
In this America’s Cup, which starts in Bermuda in three weeks’ time, Southern Spars have broadened their horizons and painstakingly built Emirates Team New Zealand’s AC50 yacht, from the wing sail, to the twin hulls, right down to the hydrofoils.
But this latest change in tack began with a different sport – when Olympic rowing gold medallist and former America’s Cup sailor Rob Waddell walked into Hauser’s office inside the sprawling Southern Spars factory early last year, armed with a couple of oars.
Waddell, chef de mission for the New Zealand Olympic team in Rio, wanted to see if Southern Spars could design a better oar for the rowing team.
“We started going down that path of development, but with only six months until the Olympics, there wasn’t enough time,” Hauser recalls. “So, then he came back with a bike wheel.”
Some of the 22 designers who work at Southern Spars’ new headquarters in Avondale cut the aerodynamic wheel in half, and knew straight away they could make it significantly lighter and stiffer than the wheels being used by New Zealand’s top track cyclists. They worked with data from Cycling New Zealand and the Goldmine team of engineers at High Performance Sport NZ.
“We started to create a wheel that was pretty complex, but we didn’t quite get there with it,” Hauser says. That technology has been put to the side, to be further developed. But in the meantime, the designers still devised a new and improved wheel for the Olympic-bound riders.
They sent 32 of the black carbon fibre wheels with the team to Rio, where the New Zealand men’s sprint trio rode faster than they had ever done before, to win the silver medal.
“After the Olympics, [Cycling New Zealand] locked the wheels away; they thought they had something special, technology that they should save,” Hauser says. The wheels came out again for last month’s world championships in Hong Kong – and won five medals, including gold in the team sprint.
Rob Waddell says the wheel development has given Kiwi cyclists an obvious performance edge over their rivals.
“It’s a great New Zealand success story. At the end of the day, the main beneficiary was the athlete sitting on the start-line knowing they had a better product,” he says.
“But the partnership has worked well for Southern Spars too – being able to use their design and manufacturing expertise to do something different, that aligned with their strengths. And now a lot of people have learned that we have one of the very best centres of composite technology in the world sitting here in Auckland.
“When I saw what was achieved in a very short time for Rio, I knew it was just scratching the surface. There’s a lot more we could be doing with their expertise for other New Zealand sports to benefit. I guess we could look at anything that has a carbon component.”
Before Southern Spars had delivered the wheels to the Kiwi cyclists, Hauser got a call from Team NZ’s COO, Kevin Shoebridge. The contract to build the campaign’s single AC50 catamaran was up for grabs.
“I’d always been banging on their door to let us do more,” says Hauser. “Although there’s always plenty going on here, we could make room for it. To be honest, we’d do anything to help Team New Zealand get that Cup away from the Americans and bring it back here.”
Building one of these high-powered, precision yachts – now teetering on the brink of breaking 50 knots an hour in speed – wasn’t too far out of Southern Spars’ comfort zone.
“If you look at these boats, their parts are basically long narrow things, like a mast or a boom. This whole factory is set up for long skinny things.”
Everything in the new 10,000 sqm Southern Spars building in west Auckland is big. The 52m long autoclave – a giant oven to bake carbon composites – and a 62m long paint booth – where both AC50 hulls could be lined up end-to-end – are the longest of their kind in the Southern Hemisphere. It is also a place of exacting precision – every millimetre of paint was measured for every coat on the Team NZ boat to meet the tight weight specifications.
Making the boat’s hulls, which are all an identical design for this America’s Cup, was far from the most complicated part of the job. The two complex wing sails took 15,000 man hours to complete; the rest of the boat, just 14,000.
Hauser says he and the Southern Spars staff (up to 300 in Auckland) were kept in the dark about Team NZ’s plan to install pedals and bike seats to power the boat. “Whenever I turned up at their base, [Olympic cyclist now grinder] Simon van Velthooven would have to go hide out the back. I saw the sailors’ body shapes change, but I honestly had no idea. I think it’s great; there’s a lot to it.”
Masts are still the company’s core business – from superyachts to Olympic dinghies. They’re now making spars for all eight boats in this year’s round-the-world Volvo Ocean Race. Around 1000 people are employed throughout their manufacturing and servicing facilities in Auckland, South Africa, Sri Lanka, Spain, Denmark and the United States.
But the pedal-powered catamaran and the cycling wheels have “opened a lot of doors” for Southern Spars, as they continue to look for more composite work outside their norm. They’ve been building carbon parts for Pacific Aerospace in Hamilton, to help reduce weight in their planes.
“We’d like to do a lot more composite work – aircraft, helicopters, bridges – and we’re keen to help make the SkyPath under the Auckland Harbour Bridge,” Hauser says. “We see ourselves as being strong in top-end composites, and there’s a big demand for them out there.”
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Sailing ahead with Southern Spars
Mark hauser, co-director and founder of southern spars, discusses the ac, carbon technology and the future of the sail….
Southern Spars are a New Zealand yachting institution, as well as a pioneer in composite manufacturing across many sectors. Its heavy involvement in the America's Cup helped drive a new wave of innovations that are emanating through the superyacht sector. Sailing superyachts themselves are evolving and growing. A sector that is underpinned by fast semi-production yachts up to 120ft, is now also seeing convention busting custom projects of immense size. Making it function as a wind-powered vessel falls largely on the shoulders of a manufacturer such as Southern Spars.
Nobody builds more, bigger than Southern Spars. Visiting its facility in West Auckland and speaking with co-director & founder Mark Hauser, was an eye-opening experience. In a two-part interview, we discuss the history and development of the technology at Southern Spars, as well as take a tour of the facility to see the production in action.
“With everything that we do, we challenge ourselves.” Starts Hauser, “We have a youngish group here, and we always have been. The team has come out of sailing, and from the start, we always wanted to be ahead of everyone else. The company has been through some changes, but that thinking is still with us.”
“To maintain that talent pool, we do a lot of work with universities and tech schools,” explains Hauser. “A lot of the team upstairs have moved through the production side of things on the floor. Many of our project managers have been with us for a long time, coming out of Americas’ Cup teams, and Volvo Ocean Race teams, it all adds to the dynamic here. We need that deep level of experience. We have had some truly massive projects here recently.”
Southern Spars is closely associated with the America’s Cup. What is less understood, is the extent to which it has worked across most of the teams simultaneously. “We became involved with Emirates Team New Zealand (ETNZ) very early on. We were also involved with the production and design of the rigs for most of the teams. The Cup itself was fantastic for us, and the rigs went through a fair amount. They were very lightweight and challenging to build. Prada dropped one because they ripped a bulkhead out, ETNZ capsized a couple of times. However, the rigs came through unscathed.”
“A lot of people think we make a large amount of money off a contract like the AC,” continues Hauser. “However, there is a lot to it. The specs change and it is constantly evolving. You end up pricing something without really knowing what you are building. It takes a lot of time and management, and the pressure really comes on with respect to timing as deliveries. That being said, it was fantastic for The Cup to be here and for the team here to see the Southern Spars branding flying past and, of course, winning it.”
Sail power must play a bigger role in a greener future for the fleet. However, as seen in The Superyacht New Build Report, the year-on-year deliveries of large custom yachts have plateaued in the last decade. The factors behind that trend are multi-layered, but a simple explanation is that the outfitting and operation of large custom sailing superyachts can be complicated, time-consuming, and expensive. Simplifying the sailing yacht systems is one of the key challenges for Hauser and the team at Southern Spars.
“We have many conversations with new-build yards where they talking about moving towards electricity or wind for their sustainability and green initiatives. And, put simply, we are the wind. Our challenge now is to develop a much simpler above deck system. We believe we have done that by working with innovative partners, such as DynaRig, and we are close to some further significant new build contracts.” Says Hauser.
“Our goal is to produce systems that give the vessel that performance, but also cuts down on the amount of above deck winches, lines and rigging,” continues Hauser “This will keep the cost down. The designers are working hard. This is our next big challenge in order to take the sailing yacht market to the next level.” The marker has been laid down by builds such as Black Pearl, and the proof of concept is there. Creating more sailing yachts that do not compromise on ease of operations and can truly take advantage of the benefits of wind power, and under sail power generation, is fundamental to a more sustainable future for the fleet.
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Obviously, a sailing yacht goes nowhere without the sails. Despite all design precautions and preparation, a new build sailing yacht has always had a period of trial and error in the final stages of delivery, when the sail and the rig meet for the first time. Hauser explains that the technology and relationships within the sector have made huge strides in this respect. “We are always looking to make the rig/sail combination better and are working very closely with the sail markers. We now can tune the rigs before we build them. We can ensure the depth of the sails vs the bend in the rig is perfect, the headsail tensions, everything. We have race boats now that can go racing without having to touch the stays. We can put the rig in the boat, go sailing that day and start training the crew the next. This has been a huge development”
The quantum leap in rigging and mast manufacturing came with the advent of carbon rigging. The strength that it afforded, via mechanisms such as the righting moment, allowed designers and naval architects to rewrite the rule book. The next big steps are more subtle, however, as Hauser outlines “There are many small advancements taking place at once. For example, TPT (Thin Ply Technology), and pre-laminated carbon, both of which have been a significant gain for us and allowed us to take significant weight out of the tube while keeping the same strength. We have always had the philosophy that if we stop evolving and innovating then we may as well close the doors.”
“We don’t really see an upper limit to the size of these rigs, and the sailing yacht sector," concludes Hauser. “Owners want to go further, be more intrepid. And we have a capability to grow with the market.”
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FINEST CARBON MASTS
A mast is one of the most dynamic and complex components of a yacht, with the job of transferring the power generated by the wind and sails into the yacht. It must withstand a multitude of ever-changing forces, including torsion, bend and compression. Yet it must maintain the perfect combination of stiffness and flexibility to maximize performance of the sail plan.
At Southern Spars we are spurred on by two key drivers; performance and reliability. The foundations of our success in these areas are sound principles of design and manufacture, combined with a detailed understanding of our customers’ requirements.
At Southern Spars, we build packages for everything from mega yachts, to race yachts and Olympic dinghies. Developments made in one area are disseminated through all of our teams, meaning the rate of progression throughout the company is extremely high.
WE BUILD MASTS FOR…
Grand prix / racing, classic cruiser.
Phenomenal strength is needed in the mast and rigging to support a superyacht’s immense sail plan. The yacht’s dimensions must be balanced with the mast and boom for both aesthetics and engineering capabilities. Modern superyacht spars have added functionality like furling mainsails, and rafts of electronic, navigation and communications components.
As superyacht owners seek ever-larger and more performance-oriented yachts, designs draw extensively on developments made in the Grand Prix arena. Southern Spars’ ECsix continuous carbon fibre rigging is now used in most superyacht projects. Thin ply carbon fibre for mast construction is also beginning to cross over the race/luxury boundary.
The many international design awards won by superyachts carrying Southern Spars’ packages highlights the vital role that our team plays in creating world-leading superyachts.
With almost universal domination of the world’s elite inshore, offshore and around the world events; Southern Spars’ race results speak for themselves.
Our dedication to performance and reliability makes us the obvious choice for racing yachts that want the edge over their competitors with a product that they can trust. Throughout the design process , we integrate the sail maker’s design into our own so that the spars and sails work as one cohesive unit. This enables racers to extract maximum performance and trust that the mast will get them across the finish line.
Southern Spars rigs are made from thin ply carbon fibre , which allows us to design tubes lighter and stronger than our competition, while achieving a more accurate bend profile.
The spirit of multihull yachts is generally more radical, not conforming to the limits imposed on monohulls. Catamarans and trimarans often seek something different and more exciting – a spirit embraced by Southern Spars.
Multihulls allow many different rig and rigging configurations, which allows Southern Spars to design innovative and often unique solutions to aid the yacht’s performance.
We work together with the yacht’s designer and sailmaker to ensure the whole yacht works together to embody the essence of multihull sailing – the perfect combination of comfort, space and effortless speed.
Southern Spars’ carbon technology allows us to build more than just masts. We produce many of the carbon components in a multihull including the crossbeams, spine, and bowsprit for everything from foiling AC72s to multihull superyachts.
One of the best ways to bring new life to an older vessel is to upgrade the spar package. Doing so will significantly increase its performance, safety and ease of operation making sailing more enjoyable and therefore done more often.
Classic yachts are great to look at, but can be difficult to sail. Upgrading to a carbon mast from Southern Spars will make an older yacht sail like new one, with a more efficient sail plan and improved righting moment. Southern Spars’ attention to detail, from design through manufacture to paint and final fit out mean that all of this can be done without compromising any of the cosmetic attributes or traditional feel of your yacht.
Southern Spars have built new carbon fibre masts for single, double and triple masted classic yachts, cutting significant amounts of weight and improving the reliability of a rig package.
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America’s Cup: Why Team NZ boat Taihoro won’t be at 100 per cent until October
Christopher Reive
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Their new AC75 might be on the water, but Team New Zealand aren’t showing all their cards just yet.
The defender of the America’s Cup ticked off the most significant milestone of their campaign yet with the launch of Taihoro , the vessel on which they will attempt to retain the Auld Mug.
While the veil was lifted on the boat last week, there is still plenty being left to the imagination.
Like most teams’ boats now, the hull shape is out in the public view . However, what’s going on below deck remains largely a mystery to the untrained eye. But even from the outside, not everything will be as it appears come time for racing in Barcelona .
Taihoro has been launched with the team’s last-generation foils, and Team New Zealand port helmsman Nathan Outteridge told the Herald there were a few surprises up their sleeves yet.
“You’ll see features slowly being added to the boat between now and October, but you won’t see this boat at its 100 per cent until October - like the America’s Cup is a design race,” he said.
Outteridge likened the process to that employed by Formula One teams, where they plan upgrades to their cars throughout the season in a bid to make them faster and more competitive as the year progresses.
In the America’s Cup, those upgrades will become a feature through testing periods and preliminary racing right up until proper racing gets under way in Barcelona in late August.
Even during the racing period, teams will take stock and look for areas of improvement, particularly Team New Zealand, who will race in the round-robin of the Challenger Series before meeting the winner in the match for the Auld Mug.
“It’s all about continual improvement. So, we’ll have new foils coming when we get up to Barcelona, and then there’ll be tweaks and modifications to the boat, to the sails, to the foils all the way to the end,” Outteridge said.
“All of those are scheduled now. You can’t just keep planning to add stuff last-minute, you’ve got to plan it months and months in advance.”
Since rolling Taihoro out of the shed just over week ago, Team New Zealand have been getting a handle on the vessel on home waters in Auckland.
It’s the first time since last October that they have been sailing on an AC75, following a block of training in Barcelona on their second-generation vessel Te Rehutai.
While they were expecting to be launching their new boat this month, Outteridge said Taihoro arrived ahead of schedule, which has allowed the team to get a few extra days of sailing into their timeline.
“It’s my first experience personally of having a boat touch into the water before its delivery date. Every time an America’s Cup team puts a date on a boat to go in the water, it’s generally later, not earlier,” he said.
“It’s been a pleasant surprise, and so far the commissioning has been going really well. We’ve had no issues with the boat at all, it’s running really well, and what that means is we can get into performance; we can start optimising the boat.”
Four teams have now launched their new AC75s, with Ineos Britannia revealing theirs this weekend. Only American Magic and Orient Express Racing Team are yet to have their vessels brought into public view. However, they are both expected to launch within the next month.
America’s Cup key dates
Barcelona Preliminary Regatta: August 22-25
Louis Vuitton Cup Round-Robins: August 29-September 8
Louis Vuitton Cup Semifinals: September 14-19
Youth America’s Cup: September 17-26
Louis Vuitton Cup Finals: September 26-October 5
Puig Women’s America’s Cup: October 5-13
Louis Vuitton 37th America’s Cup Match: October 12-21
America’s Cup challengers
Ineos Britannia (UK - Challenger of Record)
Alinghi Red Bull Racing (Switzerland)
Luna Rossa Prada Pirelli (Italy)
New York Yacht Club American Magic (USA)
Orient Express Racing Team (France)
Youth and Women’s America’s Cup teams
New Zealand, UK, Switzerland, Italy, USA, France, Australia, Canada, Germany, Netherlands, Sweden, Spain.
Christopher Reive joined the Herald sports team in 2017, bringing the same versatility to his coverage as he does to his sports viewing habits.
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Check out our facilities in New Zealand, Sri Lanka and the USA, and see how best to get in contact with us. Southern Spars News. ... Spars Welcomes Bill Hughes as Technical Director Southern Spars, leading innovator of high-performance composite yacht spars, is delighted to announce the newest addition to its leadership team, Bill Hughes, who ...
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They built the fastest America's Cup yacht that New Zealand has ever sailed, and the wheels that transported Kiwi cyclists to six Olympic and world championship medals. Now Auckland mast-makers Southern Spars want to help more New Zealand athletes on to the winners' podium, by taking their cutting-edge technology in ingenious new directions.
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Hall Spars is a leading manufacturer of high-performance carbon fiber spars and rigging for sailing yachts. With over 40 years of experience and innovation, Hall Spars offers custom solutions for any sailing project. Hall Spars is part of the North Technology Group, a global leader in marine and manufacturing markets.
Sailing superyachts themselves are evolving and growing. A sector that is underpinned by fast semi-production yachts up to 120ft, is now also seeing convention busting custom projects of immense size. Making it function as a wind-powered vessel falls largely on the shoulders of a manufacturer such as Southern Spars.
As superyacht owners seek ever-larger and more performance-oriented yachts, designs draw extensively on developments made in the Grand Prix arena. Southern Spars' ECsix continuous carbon fibre rigging is now used in most superyacht projects. Thin ply carbon fibre for mast construction is also beginning to cross over the race/luxury boundary.
Shipping and discount codes are added at checkout. Spars, Rigging, and Hardware for Sailboats. Rig-Rite, Inc. Phone: (001) 401-739-1140 -- FAX: (001) 401-739-1149. www.RigRite.com. Spars - Masts, Booms & Related Hardware. Rig-Rite stocks the widest selection of Spars and Spar Parts available anywhere, from manufacturers around the world.
Emirates Team New Zealand has returned to partner with world-leading composite specialists, Southern Spars NZ, in an attempt to beat the wind-powered land speed record. "Emirates Team New Zealand approached us and asked if we would come on board to build the wing on the land yacht. This is a huge credit to our team, their experience and ...
We are proud to have an imminent presence in some of New Zealand's most prestigious locations. 021866272; [email protected]; Contact Now. Home; Architecture; Bamar; Flagpoles; Masts; ... We have many in-house metal skills and experience gained over the past 30 years in producing export quality yacht racing and cruising masts, Yachtspars are ...
After 30 years experience we are still making the best in New Zealand THE PRESTIGE RANGE. Click on the links below to go directly to our Italian Agencies' websites. Contact Us. 161 Old Railway Road,RD2 Kumeu, Auckland - 0892. 0064 9412 7100; 021866272; [email protected]; Quick Links; Home; Architecture; Bamar; Flagpoles;
Yachtspars manufacture and restore masts and flagpoles this includes offering a diagnostic and rigging service. We are proud to have an imminent presence in some of New Zealand's most prestigious locations.
The defender of the America's Cup ticked off the most significant milestone of their campaign yet with the launch of Taihoro, the vessel on which they will attempt to retain the Auld Mug. While ...