In an unassuming metal building located just off Highway 522 in southeast Snohomish County, a radio playing pop tunes is cranked up, and the music’s driving beat fills the cavernous interior as workers go about their duties assembling a hull or sealing a seam.
Around them are a handful of aluminum boats in various stages of development, boats that may end up cruising down the Nile River in Africa or through the nearby San Juans. Boats that may be purchased by a family looking for an economical way to enjoy a nearby lake or by a yachter needing a reliable tender.
Inside this Maltby-area manufacturing plant beats the heart of Duroboat, which has been producing high-quality, lightweight watercraft for more than two decades, said Larry McPhail, who bought the business in 2001 with partner Mike Rowe before achieving full ownership last year.
“The thing that makes us different is our patented construction; most boats are riveted or welded,” McPhail said, noting that riveted boats can leak over time and in rough conditions, while welded boats have a tendency to crack. “Our little product eliminated both those problems.”
That “little product” is the Durojoint, which locks major components of the boat together inside a protective extrusion.
“The Durojoint allows Duroboats to have contoured curvatures and allows boats to take the shape of wooden or fiberglass boats and usually yields a softer ride” than other aluminum vessels, said McPhail, a 26-year veteran of the aerospace industry.
The compound curvature that is designed into each Duroboat hull strengthens the hull panel as well, according to company literature. Also, the modified-V hull “is the optimum compromise between a seaworthy ride and fuel efficiency.”
Duroboats range in length from 10 to 16 feet and weigh between 114 to 400 pounds, excluding accessories. The cost for the boat itself ranges from $1,600 to $4,500, with the full package price ranging from $3,000 to $14,000, McPhail said.
Because of its sturdy, lightweight composition, the Duroboat appeals to a broad demographic, from small-boat enthusiasts to yachters using the boat as a dinghy. There are customers who choose Duroboat as an economic choice and others who like its aesthetics, McPhail said, noting the use of high-quality urethane paint in four standard colors: yellow, blue, teal and red.
One of the markets the company wants to grow is the small family who may not have a large vehicle to tow a heavier boat and “wants to do boating without spending a fortune,” he said. “Our boats are easy to launch and use 4 to 5 gallons of gas for a full day on the water.”
Photos sent in from happy customers show Duroboats in action — pulling duty as a rescue boat in Japan, serving with a U.S. Geological Survey team in Alaska and pulling into Port Ludlow. Some are fully customized, with fishing pole holders, bow rails, and floor-mounted control consoles, among other goodies.
Others are less showy, but no less fun, McPhail said, pointing to a number of on-site Duroboats soon headed for YMCA Camp Orkila on Orcas Island, where they’ll serve as row boats.
Each year, Duroboat’s staff of six manufactures between 200 and 300 boats, which are sold through some 30 dealerships in the United States and abroad, said McPhail, whose goal is to double production but plans to grow “in small pieces while looking for a big opportunity.”
“We’re looking for creative partnerships, creative dealers — the core of it all is a unique and excellent product,” he said.
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