A dozen shipwrights laboured with love for over a year to hand-finish every detail. First, they travelled to the island of Thasos in search of the strongest, straightest pine trees to build the hull and mast. The resin in the pine keeps the wood supple. After felling the trees, the logs were submerged in the sea for several weeks to temper and strengthen the wood. When the logs rose to the surface, they were ready to be bent and planed into shape, piece by piece.
There was no model or blueprint. The boatbuilders laid out the design from instinct and experience, guided by generations of wisdom about the local winds and waves, currents and customs. With no automated machinery, it was rare for a kaiki to have an engine at all — let alone two Rolls Royce engines, which are still in use today. Specialist craftsmen took care of each stage of the process: the lofting and rigging, cabinets, and sails. As a mark of respect for these craftsmen, the original layout has been maintained, every detail meticulously preserved.