Aluminum Boat Build From Scratch - Ep. 1

[@modularhippo]

Ready to see a 36-foot aluminum boat come to life? Follow along as I build it step-by-step!

[@jiggles1722]

You're a genius man ❤

[@modularhippo]

Ha Ha, would not say genius, maybe stuborn:) Happy 2025👍🏻

[@aadamskii]

Very informative, thanks for sharing ❤

[@modularhippo]

Hey Aadamskii - Thank you for taking time to comment and happy to hear that you enjoy the content:) Happy ending to 2024 and hope we all will get a great 2025!!:)

[@captainheather]

Excited to see this come to life! I have been living and working on Aluminum Boat For the last 10 years and also helped Juho and Sophie on Alluring Arctic find the aluminum expedition boat that they’ve sailed through the Northwest passage just recently. In addition, I captain a wooden tall ship with the first hybrid electric engine for its size, and I am intimately familiar with the benefits and pitfalls of electric motors at this point, so I’m really curious to see how your build and your electric motor integration come out!

[@modularhippo]

Hi Richard - Pleasure to meet you!! You sound like someone I should have spoken to before taking on the project, ha ha:) I have followed Juho and Sophie's adventures. The environment they are in speaks to me as I lived in the arctics for a while (and native Swedish). Internet is a gold mine of information (both for and against so you just need to sieve out what works and makes sense for you). From what I have seen so far a reliable backup generator (or two) is a must from a safety-range perspective:) - My build is fairly slow but a labour of love:) I have Subscribed to your page so that we can stay in contact as have a feeling our paths will cross again at some point:) Thanks Richard!

[@snibbo2000]

Looks interesting! Good luck with the build. (Btw, I believe Kiribati is pronounced Kiri-buss).

[@modularhippo]

Hey, thank you for your kind words and you are right, it is pronounced the way you say:) Just need to get my head around it as said it the wrong way for ao long now😅

[@c.a.mcneil7599]

Look forward to see how this bits of aluminum becomes a beautiful boat.

[@modularhippo]

Hi C A McNeil, thank you for comment and tuning in:) Small parts created has just started to actually look at something that resembles something that could be long to a boat which is encouraging:) Just about to weld the keel-box front half with the back half (front half contains the keel bearing parts so took some time to finalise that one and to make sure everything is straight'ish:) - Thanks for watching!!

[@maurolimaok]

Bacana! Muito bacana. Mais um projeto do Cabinho saindo do papel. Parabéns.

[@modularhippo]

Thank You Mauro!!:)

[@captainheather]

Excited to see this come to life! I have been living and working on Aluminum Boat For the last 10 years and also helped Juho and Sophie on Alluring Arctic find the aluminum expedition boat that they’ve sailed through the Northwest passage just recently. In addition, I captain a wooden tall ship with the first hybrid electric engine for its size, and I am intimately familiar with the benefits and pitfalls of electric motors at this point, so I’m really curious to see how your build and your electric motor integration come out! Where are you located?

[@modularhippo]

Hi Richard - I am Swedish but lived in North Wales (UK) for 20+ years now so maybe call me 'Swenglish':) As I am a part-time weekend builder it may take a while but I am stubborn so will get there:)

[@Marread]

Good luck, look forward to watching you go!

[@modularhippo]

Thanks Marread!! Hopefully get to sail the end product one day😅 By the way Dave Grohl is a legend!!

[@MrCelsoSan]

This project from Luis Manuel Pinho is fantastic, and result of years crossing oceans.

[@modularhippo]

Hi Mr CelsoSan, thank you for taking time to comment. That is what I love about the history of this design. Many years of actual sailing and real life experience has resulted in this updated version of Kiribati 36. Labour of love!! Thanks Mr CelsoSan!

[@svlamancha9877]

Looking forward to following your build. Good luck. Do you have access to a build shed? 👍

[@modularhippo]

Hi Svlamancha9877 - Thank you for tuning in and for taking the time to comment. At the moment I have an old lorry-body on a field where I store finished parts. It is large enough for me to do extrusions and other external & lose parts. I have not yet decided on final building place for the hull itself and this my plan. Finalise everything to a point where I have all parts, bulkheads and metal lined up. At this point I can rent something short term why I assemble the hull. This should save me some cost as I do not have to pay for a unit and look at a hull when I create all the other parts. Some starts by building the hull, I would mentally struggle to see the hull when done and after that very little visual progress for years while working on the other parts. I guess either way works:)

[@MarciusLage]

B&G Yacht Design have the world best aluminium boats projects. Better them any other.

[@eduardgindin3763]

Generally speaking, yes. But META boats are also very interesting. In fact, I'm very interested in one of their designs, namely Sainte Marthe 39 that is built in Strongal method, namely, thick plates and fewer stringers.

[@Ronaldo-mu9ed]

Parabéns, são projetos muito famosos aqui no Brasil!

[@modularhippo]

Olá Ronaldo, obrigado! É um lindo veleiro!!

[@kiteattack3947]

so nice ! i'm one of you'r 556 subscriber and i'am a sailor instructor lol such a nice project !

[@modularhippo]

Hey Kite Attack!! Thank you for subscription and for taking an interest. Doing a bit of Paragliding on the side so subscribed to your channel as I hope to one day also try Kite Surfing:) Thank you for tuning in:)

[@christophmahler]

I had just noticed that the plywood kit for the Transat 'Globe 580' (5,80 m length) comes at 8500 USD which would cover a well fitted used boat of a similar size (although lacking the distinct features like traversable, watertight bulkheads). A detailed cost run-down may help beyond the actual build to get a grasp of the maintenance cost in case of structural damage or deep refitting, possibly helping to figure what size and complexity of a boat, one feels comfortable to maintain (of which I'm not sure).

[@Cptnbond]

Thanks for sharing all your detailed calculations. That was a unique take on all YT-DIY boat builders. I will follow your progress since I'd like to be challenged by a similar project. The keel was steel, correct? Cheers.

[@modularhippo]

Hi SGT Bond, thank you for interest and for taking time to comment as appreciated:) Spent many years trying to understand the cost and 'hidden' costs in a DIY project and was extremely hard to get any figures so thought I track it in the hope to help future builders:) For this design all my parts are 5083 (marine grade) aluminium (bar from parts related to propulsion etc.). Saying that allot of good design out there in steel. Will just require a bit more maintenance once in water but bar from that very similar as far as process goes. Any questions you know where to find me:) Thanks!

[@keyem4504]

Looking forward to this. Sounds like a great project. Just wondering how you want to avoid galvanic corrosion between the lead and the aluminium in the keel.

[@modularhippo]

@keyem4504 Thank You:) The lead will be painted in two layers of epoxy resin, and the inside of the keel boxes will be dressed with a 1mm Neopren fire retardant matt. That is the plan for now:)

[@usernamegoeshere527]

@@modularhippo Wow, I had been looking at these designs just a month ago and fell in love with them. I am super excited to watch your progress. On a similar note to keyem4504, I noticed that you said that you were going to be using a steel key on the rudder shaft. Will you be insulating that in any way to prevent galvanic corrosion?

[@modularhippo]

@@usernamegoeshere527 Hi, Thank you for taking time to comment and super happy hearing that you have the eyes on the same design:) There is a key-steel on both the tiller stock, and one each on the rudder stocks. Wherever I cannot separate AL 5083 from 316 Stainless I will use as much Sikaflex as I possible can to create a membrane. Saying that, Key-Steel are known to rust and would say that they will be parts that needs inspecting at least once a year. Worst case they should be easy to replace and key steel is not expensive so all good on that front:) The tiller and rudder clamps themselves would most likely be strong enough without the keel steel design but prefer it with for peace on mind. The first original Kiribati 36 worked fine without so it is a bonus on this updated design:) - Let me know if you take the plunge as would be great to follow your build:) Thanks.

[@usernamegoeshere527]

@@modularhippo Ha, nothing a good helping of Sikaflex can't solve. I most likely am a few years out from starting myself, but I did find someone else building the same design on facebook. I am sure there is some useful information you could glean from their work so far: BarrasYachtFactory

[@johnhockings]

Looking forward to following your build. Good luck! Please note, the boat is pronounced Kiribass, not Kiribaty. I know because I speak the language of those central Pacific Islands. Cheers.

[@modularhippo]

Hi John, that is amazing information, thank you!! On the same topic, do you know if ot is the name of a place or an object? In other words do you know what ot means?:) Big thank l you for comment and the unexpected info:)

[@albertfunk1176]

I have forwarded the post to serious channels. :)

[@modularhippo]

Hi Albert - Thank You, very kind of you:)👍

[@yarpenzigrin1893]

Pretty nice boat although I would have modified the design with twin unstayed junk rigged masts.

[@modularhippo]

I must say that I do like junk rigging but for this one I will stay on plan:)

[@DanielKoolboy]

🎉🎉🎉

[@modularhippo]

Hey Daniel, Thank you for comment and for tuning in:) Enjoy your Saturday evening!!

[@AnikDasofficials]

Really amazing content bro. I want to talk with you.

[@albertfunk1176]

For my Reinke 13M, I cast the two aluminum keel molds with lead in a foundry. This was also the recommendation of Mr. Reinke and all other shipbuilders. A cavity sealant was sprayed in through a sealable opening. This sealable opening is also needed to weld the keel. After 23 years in the water, there is no problem in this respect. I recommend testing whether it is possible to weld anywhere near the sealing compound. Even the slightest contamination prevents a clean aluminum weld. The finished parts look very good. Ultimately you will need a hall, do you already have something in prospect? We plotted the 1:1 parts on Mylar film (PET), which is largely distortion-free. Good success!

[@modularhippo]

Hi Albert, big thank you for comment and some VERY interesting ideas. Are you saying that you closed the keel but left opening into the lead compartments just big enough so that the lead could be poured directly into the aluminium keel? Once lead was in place you then used the cavity sealant before closing (weld) the small openings to completely seal the keel? If that is a proven method then it could save me a ton of work casting and prepping each of the 21 blocks I need for the keel. If you can point me in the direction of any material published using this method (or maybe something on the web) then super grateful. In relation to a hall, I am playing with the idea of a makeshift 'Poly-tunnel' style setup on a field behind my house OR renting a derelict barn as I have allot of farmers in area where I live. Will have to weigh up the costs/travel times and any other factors when time comes:) Thanks again!

[@albertfunk1176]

@@modularhippo You're welcome. You're one of the few people in the world who seriously wants to build an aluminum hull himself. Further answers and information are sent by e-mail.

[@modularhippo]

@@albertfunk1176 - Seen the email, Big Thank You!! Will be some interesting bedtime reading:) Enjoy your Sunday and Thanks again!!:)

[@clivestainlesssteelwomble7665]

A point to consider now is site security.. you need to protect your location. Vehicles Materials and tools will make a tempting target to some unsavoury types that also like picking off farms and farm equipment. Plus unless its very close to home you will spend a long time going back and forth loading and unloading..kit. Ive experienced it building kit cars...and even a short trip gets difficult at times ... You also need to be able to keep an eye on the build and not get caught out by the barn owner decieding they need a change of plans. Check out Tentmaran sailing and how Arrie he's Dutch treats his trimeran hulls..so they need no antifouling.

[@modularhippo]

@@clivestainlesssteelwomble7665 Hi Clive, good points. Getting my tools nicked would set me back not only in time and money but also mentally. It is all leaning towards building a temporary poly-tunnel structure on a field I have access to behind my house. It would be some upfront cost to flatten area, and to put a concrete slab in but once done and the structure is up that should then be it. Travel to and from a rental location I believe would put allot of time on the project so a good point as well. Thank you for letting me know about Tentmaran Sailing, will definitely check that out now:) Thanks again!

[@samijokinen6923]

👍🏻

[@modularhippo]

Hey Sami! Thanks for tuning in:)