Building an Aluminum Boat - Design Part 1 with KM Yachtbuilders | EP 203

[@thylacine1962]

Im going to follow this series with great interest. Your already very different to other sailing channels. They are aspiring to have multi hulls and some are now making that dream come true for them. How ever you 2 are staying mono hull, staying with the swing keel and getting a custom aluminum build. The interest you are generating with this project is phenomenal. Rock on you 2. Good luck.

[@DistantShoresTV]

Thanks, PJ! So glad you are enjoying these videos. More to come!

[@lbb101]

@@Tohva2881S/V Volt, a Viator Explorer 42 DS, is designed by Berckemeyer Yacht Design, the aluminum hull was built by Jachtbouw Folmer (NL) and the interior and outfit was done Jachtbouw Pronk (NL). For the German speakers there is an amazing blog elaborating all their decisions (volt-at-sea.segelnblogs.de), sadly neither the Volt Blog nor the Viator website are there in English. Or at least, I couldn't find the English button. Because as and hybrid, high-latitude capable, double engine, double rudder, couple deck salon couple cruiser, it is an interesting competitor with the Boreals, Garcias, Huttings, and Bestevaers. But I guess the market there is so small that they'd need to go international (English).Alone for the price tag of these boats.

[@ByronWalter]

I fully understand. I had mono once myself.

[@williambunting803]

I love this conversation. While you were talking I realized that if I move the nav table aft 250mm on my Southerly 135 I can have 2 people facing each other on the nav table for working as Sailing Uma do for their editing. Also if I change the aft cabin door arrangement I can build a work table there, though not sure how comfortable that would be. In both heads on this boat I have installed a fan heater powered from the Eberspacher Hydronic system. That means that after a shower I run the heater for an hour and that recharges the hot water in the new Vetus 45 Ltr 0.5 degC /hr heat loss cylinder and dries out the head so it is not a permanently wet head. That works well and I am thrilled with the Vetus cylinder after the absolutely disasterous original “calorific” which I didn’t realise for more than a year had virtually no insulation and cost me Eu 1000 in wasted electricity. One of my favorite ideas that you might consider is, following the new trend in domestic refrigerators, to have a fridge access above the galley counter level to allow quick access for items such as milk, butter, cheese, juice, ,, without opening a main door into the fridge. It is tight to fit in my 135 which really needed an extra 100mm of freeboard to be a brilliant boat, but I can make it work. Another galley tip is that there is always wasted space behind the stove so to get to that space I am making the stove hanging space a pull out stainless steel drawer (with the stove gimbaled within it) so the space behind the stove becomes the storage for the big pots and pans. It also means that I can build a powerful extractor fan to eliminate the cooking oil mess that accumulates above the stove on everything. The other project that I am committing to right now is to buy 500 M of the excellent tubes that you can see at [e-mail] to make a very thin heat collecting array to bond to the back of my Panasonic PV Panels to make them PVT’s. There will then be oil circulating through these panels taking heat from two of the solar panels to a heat exchanger at the Vetus water cylinder. With this system I may never have to run the Eberspacher or the Engine to have forever hot water. My solar panels are also arranged to tilt for low sun angle as well as to be better water catchment. The final project that I have underway is a design for what we call a Black Waste reactor. This is a device treat black waste flush by flush in a bout 10 minutes to make the waste compatible with new NL regulations. The units will be about 250mm in dia and up to 200 mm long. The suggestion is to lay in some heavier cable to the head region to make it possible to install such a device when they become available. This device will effectively bleaches masserated waste to kill all bacteria and viruses making it safe to put overboard. I know you will have great joy with your new project and I will be watching along with you. BB

[@johnsmith4066]

KM are superlative quality boat builders. We were privileged to have a boat built by them a few years ago.

[@KMYachtbuilders]

Thanks John! :-)

[@Tomm9y]

Building in aluminium offers such flexibility in design. I can see the length stretching to 53' with the scoop and large cockpit. Thanks for sharing this interesting process.

[@DistantShoresTV]

Yes it’s interesting seeing the aluminum process and we’re looking forward to seeing it in person in a couple of weeks. We’ll report on the rest of the process as well🙏🏻🤩

[@philliporeilly901]

I turned up at KM in 2019, simply to perhaps get a pamphlet or have a look at their excellent models in the front offices The welcome was extraordinary and I was given a tour of the works and an inspection of their current Bestevaer Pure 45. Every boat under construction was magnificent.

[@mz2288]

Thanks and shout out to all of you in sharing this exciting journey with us on KZbin!! One thing I really love about your current boat is the modern high quality interior finish, your boat really feels like a luxurious home and it must be very comfortable. Can’t wait till the next episode!

[@leeboggs269]

This is such a highly intelligent way to embark on a boat build. Thank You so much for the process! Take care you two and happy sailing

[@fransdriesen1311]

Isn’t this a win win…One one side the "Distant Shores" hands on experience in almost all sailing and weather conditions and on the other hand a builder that can translate all that experience into their hallmark building technology and process..The proces or roadmap you are following to achieve that is outstanding..

[@DistantShoresTV]

Thanks for this inspiring comment, Frans!

[@donnakawana]

In my wildest dreams KM wud be my choice!! Your quite an inspiration to someone like me... I'm working on recovering from major fire... So I have nothing to sell now to buy a boat. An savings went to survival... So working on figuring out starting from 0... But you guys are inspirational ✌🏻💗😊❣️

[@thearchibaldtuttle]

Building a boat with KM is like ordering your customized RR!

[@jordanharkness]

Yes, I've definitely dreamed of building our boat rather than buying someone else's dream boat. I've always assumed that starting from scratch would increase the costs beyond reach. My question is how much extra cost does it add over a production boat; when a garcia 45 is my dream boat, the cost is already astronomical... how much extra does it take to design all the custom bits on top of that? P.s after watching your raves about the Southerly, I was surprised to hear you were moving on so quickly. What was lacking that makes you want to move on so soon or is that something you can't share?

[@vandijk1698]

This is great! Always been interested in an aluminium Dutch custom build, just subbed. I hope you enjoy this wonderfull experience, thanks for taking us with you...

[@xtransam9970]

Thanks you for sharing your future new sailing vessel, there is no better way to feel at home, than customizing and personalizing the boat, congratulations you have great idea....

[@DistantShoresTV]

So glad that you are enjoying this new video series, xtransam.

[@oldskull70]

So exited to watch the survey to pre design ! Always important to define the upper requirements and apply to the new product ! As an aircraft development engineer I love that part of the project ! Thanks for sharing ! Can’t wait for the next milestones !

[@DistantShoresTV]

Thanks Fabio🤩 yes we’re super excited also. We’re having fun with the design at the upper level to make sure it’s the best possible boat and also looking forward to the detail spec which will need to be as complete as possible. It must be amazing to see an aircraft come together from your design!

[@oldskull70]

@@DistantShoresTV , there’s a lot of things that are the same - but , of course each one has own regulations and requirements . I love sailing too and I’ve been learning a lot with videos like that ! The trade off decisions for limited space , equipments , sailing design weight and balance ! All of these are compromising decisions ! In the aircraft development we face the same situation ! Other interest thing is to see you that already sails thousand miles and the KM builder with more than 80 projects ! A lot of knowledge and wonderful decisions and discussions ! The most important things is that pre definitions like you are doing ! I am sure that the final product will be great !!!!! Cheers ! And thanks for answer me ! I am very happy with that ! P.S. I downloaded the survey and will make my ideas to practice ! Hahahahha

[@mariuszkijowski2180]

Great video! Thank you for all the comments what you love in your current boat :)

[@billfournier439]

Awesome series you have! Will be watching it with a keen interest!

[@DistantShoresTV]

So glad you are enjoying this series, Bill. More to come soon...

[@petertorrey4080]

My observation is.....your wish list seems to have been already satisfied with your Southerly....besides the aluminium. I understand sailing around ice can be problematic with fiberglass..so, my question is....what were you dissatisfied with the Southerly? Was it primarily fiberglass vs aluminum? Looking forward to this portion of your sailing/build adventure!

[@smulismuli7976]

Was thinking the same. Feels like we need new material to feed the feed

[@DistantShoresTV]

We have always wanted an aluminium boat. There are many features we love about Southerly Yachts which is why we've owned 3 but there are always compromises so that the manufacturer meets their agendas. Sometimes things that sell boats at boat shows are not great at sea. The Southerly 480 has a lovely aft cabin but it wastes space and compromises the technical room access. The scoop is too small for our needs and the we'd like better performance.

[@petertorrey4080]

@@DistantShoresTV Thank you for the in depth reply. I was wondering about the sailing characteristics of Southerly yachts. I cannot wait to see what you and KM come up with!

[@SailingSisu]

Pretty exciting stuffs! I do have a feeling that you are focused on the keel? Did you had a bad experience with fixed keels? I saw the clip where it looks like your rudders are in the sand...where were the keel at that moment?

[@pierreberglund4059]

Wow - KM seems to be a good choice of yachtbuilder.

[@DistantShoresTV]

Yes, we have been enjoying working with KM Yachtbuilders, Pierre.

[@BigRedNZ1]

I just need to win lotto and I’d be knocking on their door

[@jandropmann3916]

Really exciting to follow your journey! I have very similar needs and desires in a boat especially the raised deck saloon. Would love to hear your thoughts on Sirius DS40 yachts?

[@paultabone2010]

So happy you are both back 🎈🦋🍷🍷

[@miked5563]

Ditto

[@DistantShoresTV]

Thanks Paul! We’re getting back to regular posts as we get more into the new build 😅

[@paultabone2010]

@@DistantShoresTV well I can’t wait to see your new dream yacht ⛵️ on the water Cheers 🥂

[@dollarette]

My favorite KZbin videos are the bulkhead fiberglass repairs. They remind me of Hamburger Hill and Platoon movies.

[@TonyK3130]

Part 1 is great. Anticipating Parts 2, 3, ...

[@DistantShoresTV]

Coming soon, Tony!

[@lambert5864]

Very interesting to follow, thanks for sharing! Listening to your wishes I think it will be a good challenge for both you and KM to fit it in a sub 50ft yacht. Aluminum yachts always have way less interior space compared to fiberglass yachts. Are you only looking at Bestevaer yachts designed by Dykstra or also Stadtship (vdStadt)? You showed an image of a Stadtship in the video for the stern example, never seen that on a Bestevaer. I am also interested in why you want an aluminium yacht, wondering if you will choose the ice rated hull option for future adventures and safety. KM builts amazing yachts, I have visited a lot of their yachts over the years during their open days. Not only great aluminium builders but the interiors and technical systems are really good as well! Again, great to be able to follow your process and see what you will come up with!

[@MrGgraham76]

interested to see this design evolve. great video.

[@ulanakeer7345]

Dreaming of the day to meet you both in person. Would love to sail with you in your new distant 4 sailboat. Very interesting video today!

[@Abc-kf4qx]

Hi guys, love coming along on your journey with this new boat. What are your thoughts on a furling mainsail? Love the aluminum build, I’m sure it will be amazing!

[@DistantShoresTV]

We have really been enjoying the furling mainsail but even though we haven't had any problems with it, we worry about it possibly jamming sometime. Since we're going to be cruising in remote areas, at this point we are planning on going back to a more traditional mainsail and stackpack.

[@cory0702]

This is excellent information on buying a boat

[@Tohva2881]

I don't know whether you have it on your radar yet, but I would like to recommend looking at what the guys from Viator Marine are doing with their Explorer 42 DS. The aluminium hull is also built in the Netherlands. Surely, the approches here are different; cruising vs exploring. But I see a lot of overlapping concepts and ideas. Other than Alubat or Garcia, Viator built their boat with a visionary idea in mind. They call it Next Generation Yachting...

[@DistantShoresTV]

Hi Hendrik. We are looking forward to coming to see your boat when we're in the Netherlands in a few weeks.

[@Tohva2881]

@@DistantShoresTV not my boat though, but good to know that I sound like I am their social media guy. Anyway, the Volt (name of the boat) lies in Stavoren as far as I know. There was a report about it from the German magazin YachtTV.

[@Frejalab]

WAUU. Exciting process. Thank you for showing us

[@stevetsigounis6535]

Love all your videos! So professional! Keep it up!

[@ABeriault]

Wow...what a lovely process! It is a bit like dreaming my own boat! Cheers

[@sailing.not.dreaming]

When does your current boat come for sale? I live in North Holland and I think they make the most beautiful boats. Southerly was on my shopping list, why change.

[@hansmuller1846]

Will you want to / be able to share something about the costs of the process or different variants you are considering? I'm trying to find out whether it would make sense to just have a boat custom built versus modifying a used one until it fits, but I'm a little too far away from that to feel good about talking to yards yet :)

[@johndeveaux7670]

Loved the initial process, end product is gonna be amazing. What are you considering for engine power. I am totally fascinated with electric such as Oceanvolt or Torqeedo.

[@DistantShoresTV]

We're working on this. We don't feel full electric is here yet for the type of cruising we do so are looking at hybrid options. Watch this space as we develop this idea. We're working on something innovative. 😉

[@Zoot1343]

Thx, looking forward to this series, best, Adam, Tofino.CA

[@DistantShoresTV]

Thanks for this positive feedback, Adam.

[@bendixon2898]

Is this a modern design hull carrying more beam aft as this gives a more powerful performance. I see all the quality builders going this way.

[@DarrenBainbridge]

Sound like you want a ameldy, an aluminum version of a Moody 54 Deck Solon crossed with a Amel 50.

[@enricpuig1502]

Excelent content! Happy to hear fresh news about your new boat!

[@G11713]

Any underwater inspection cameras (for propeller, keel, hull, tackle) and forward sonar (with due regard to aquatic life noise pollution)?

[@markhwl8345]

Great video and information, thanks guys

[@sjd9214]

Is there a video explaining why your moving towards a new, more utility style aluminium boat? Your Southerly 480 seemed to be a perfect and comfortable sailing yacht and home.

[@CHRIS198490]

Can I ask why you decided to have aluminium boat after more than 30 years of sailing in grp boats

[@tomwilliams8675]

I didn't realize you were still down in Panama. My wife and I are considering to become expats there. Looking forward to build.

[@DistantShoresTV]

There is a nice expat community here, Tom. I think you will enjoy Panama. We are! 🌴🌺🦜🇵🇦

[@justsomeit5818]

Why did you go with a custom one off? Did you consider one of the production Aluminum boat builders like Alubat or Garcia/Allures? The Garcia exploration line is the ultimate expedition yacht. It has everything your looking for plus it's built like a tank and can break ice. Its what Jimmy Cornell sails on ^_^

[@TT-tn1dp]

Outstanding content that has really helped me think too, so looking forward to more. Have now subscribed!

[@DistantShoresTV]

Welcome aboard! So glad you found this video helpful, T T.

[@thomasmoriarty6741]

Welcome back safe travels⛵

[@gidge34]

Can’t wait!!!

[@soaringblackbird4431]

I love ya guys! So happy for you!

[@DistantShoresTV]

Thanks, Soaring Blackbird!

[@michaeldobson8859]

Oh yea the dual track jib for wing and wing on the jib! Don’t forget. Plus dual anchor rollers for twin anchors at the ready, including a dual anchor locker to keep the chains separated. You need direct access to a forward sail storage locker near the bow. This way you can fly a chute more easily by passing it directly up the forward hatch, or land a sail directly below decks. Electric winches all around, with remote control on the primaries. Too many things to list.

[@RA-gk5zg]

Thanks for this great insight into custom boat building. I look forward to more episodes. I am seriously considering doing the same as no production boat has all the features I am looking for. One big question is cost. Can you give us an idea on cost vs buying a new boat of similar size? If the costs are the same then it is obvious to go custom. If the cost is prohibitive I can accept a few compromises in a production boat and keep the money saved for cruising.

[@lambert5864]

Around 1 million in euros starting price.

[@stevetsigounis6535]

OMG your serving muscles! Love them!

[@martigrey5872]

Seems like you're looking for a Garcia 45 or one of the other similar boats?

[@markgwilson]

Congrats on your new boat! I'm curious, did you looked at the Orion 49 as part of your research? Thanks!

[@SailingLearningByDoing]

Awesome video guys, would love to be in the position to build an Aluminium boat one day.

[@markpaweena781]

Would you consider an aluminium catamaran?

[@Andy_M986]

That's what I want, a big one,diesel electric propulsion, incinerator toilets,solar power,all the fruit.

[@michaeldobson8859]

Perhaps a grading system could have been applied to all the different subjects reviewed for design and construction. Something like a 1 - 5. A 1 being low priority and a 5 being a must have. A 3 being a yes we want but we are flexible as to how it’s implemented.

[@johnny_123b]

Help me understand, why would custom aluminum boat be better than production fiberglasa one?

[@psotos]

So what is the approximate price range of this new boat going to be? I am guessing 1.5 million USD.

[@brianjohnson8967]

So the lifting keel provides for sallow draft, but does the shape and strength of keel box allow for beaching ? If so is beaching actually routinely done by current owners ?

[@DistantShoresTV]

Yes, the current owner beaches the boat routinely and the shape and strength of the aluminium makes it work well according to his reports and those of others with the same lifting keel configuration.

[@brianjohnson8967]

@@DistantShoresTV Thanks for the info. My wife and I are planning on touring KM (and also Boreal) in November and will be sure to mention you guys when we do. Brian & Ellen. PS the lead time on delivery is crazy long but I guess that's always the case....

[@viatormarine]

I was missing a main argument in "swing keel vs. lifting keel". With a swing keel you can only sail with the keel down position. So you will always have the maximum draft when sailing. With a lifting keel you can sail in any position, even half down or up. It is a really important feature when crossing a sand bar or some shallow area, you just lift the keel and continue sailing. It works very well.

[@KMYachtbuilders]

Hi Hendrik, our swing keels are fully ballasted (unlike many others). So it is possible to sail with the keel in various positions (up, half, 1/3, 1/4, down or any position somewhere in between). Of course, this is relative to the overall wind conditions and the best sailing qualities will be when fully down (as the weight will also be down). But it is not only down or up as you say. We can add this to the next video interview.

[@viatormarine]

@@KMYachtbuilders thanks for the explanation. I know from other manufacturers like Seascape or Pogo, that they explicitely warn only to sail with the swing keel down.

[@scyz2807]

I've been wondering where you'd gone. Are you in Panama again/still? I know that SV Delos is down in the area. If you are there it might be cool for you to do another interview with them about their plans in addition to your plans for your new boat. Scott W

[@DistantShoresTV]

Yes, we are hoping to meet up again with the SV Delos crew while we're all in Panama. They are in the Bocas del Toro Islands of Panama and we are on the mainland at the moment.

[@scyz2807]

@@DistantShoresTV If you are able to meet up with SV Delos then you will get to meet Sierra (aka The Little Nugget) and the other members of the "girl crew"! Sierra was just a "bun in the oven" when you talked with Brian and Karin the last time. : - ) You will fall in love with the Nug very quickly!

[@colinfraser3998]

Apart from the galley the Garcia Ali yachts seem to fulfill your needs

[@DistantShoresTV]

Garcia's are great boats for sure, Colin.

[@johnny_123b]

You could have a look at Pegasus 50 by Slovenian yachtbuilder. Its a very unique carbon yacth

[@jeg5438]

I've never understood why aluminum and fiberglass boats cost about the same per foot. Can anyone explain?

[@Steve211Ucdhihifvshi]

Ive often wondered if it would be possible to build a fibreglass yacht with a plastic outer skin

[@Steve211Ucdhihifvshi]

no idea why i think these things, id need to sell my body /organs to get on a boat or become a master criminal to afford anything like this.

[@williamdykes2750]

High on my list would be accessibility and maintainability of every major system. I'm sure this is high on yours as well.

[@mentonish]

The overlay comes from someone who knows his job. When moving home the same goes for the placing of furniture in small areas.

[@elinys2843]

Think you’re looking for the Garcia Exploration 45

[@DistantShoresTV]

A great boat, yes, but we find the interior rather linear, Eli. We felt cramped in the space of the Garcia 45 but their owners love them and travel comfortably and safely long distances in them.

[@francocava8985]

A custom boat is always a risk, several troubles will surely arises after the boat will start to sail. A standard boat can minimise troubles thanks to knowledge and statistical countermeasures .

[@Psychobilly]

How’s the build coming?

[@DistantShoresTV]

We're just finalizing the design, Blair. Build to start as soon as we give the go-ahead. Thanks for your interest.

[@paratyshow]

👍☑️ Very interesting, tks.

[@mechanicallydisadvantaged1297]

yes i have

[@billhanna8838]

ME's thinking you have the best boat now , I just delivered a Hanse 505 2 year old with ALL the bells & whistles & found it wasn't the best for long passages , Great for a marina ?, Be careful of what you wish for. Is there any particular reason for up grading ? Sometimes an old woolen blanket is the best .

[@tonynotstated695]

When ever you guys decide to sell your current 480, please send me a message. I'd be very interested.

[@kengood4466]

Up to now I had thought the French were the premier builders in aluminum. Not so sure now.

[@michaeldobson8859]

Don’t forget the bow thruster and stern thruster

[@davidvanfrank6423]

Hi Paul &Sheryl, I have been following your sailing adventures since the beginning. Love hearing your design criteria for Distant Shores IV. I don’t know if know of the Sirius 35DS, but that boat is one of the most innovative and smart boat designs I know of for use of space and sailing functionality (web: www.sirius-werft.de/wpsirius/en/yachten/35ds/ KZbin: kzbin.info/www/bejne/r17ZXptrZbCNna8 ). This boat is only 35 feet but has so many of the features on your wish list: Raised Salon, Nav station/Pilot house, Galley near the centre of motion, Owner’s cabin near the centre of motion and separate from the V-berth, separate space in the owners cabin possibly for a small desk, Sugar scoop with telescopic ladder, dedicated lifeboat stowage, The 35 has a separate shower, but being only 35 feet, they fit only one head. Another innovation to make the cockpit feel large and functional is the canting wheel replacing dual wheels. The “split-level” design allows for good sight lines, separate engine room, and efficient use below decks. The Sirius 35DS is only 35 not 50 feet and GRP not aluminium, but I think it could inspire some design choices for Distant Shores IV.

[@barryholiday8998]

Seems like they are happy with their current boat so not sure why they are building a new one.

[@johnq.public2621]

🙂👍🏻👏🏻👏🏻👏🏻

[@jamescapstick916]

she was a morning gloryu 11.5 m with center board. their was corrosion on deck under tbs covering swetting in the tropics an d not well insulating lead which deformed centre board. dont get me wrong on this subject i like aluminium bu it is a worry.

[@dollarette]

Watching $100,000 decisions is exciting

[@andre1987eph]

They need a bigger boat to accommodate their guests comfortably in the way they describe. 55 feet minimum

[@tomriley5790]

Wierd clicking noise around 10 minutes.

[@suzannemccarty6057]

The biggest problem is having too many people on board.

[@ib8883]

Garcia

[@DistantShoresTV]

Yes, Garcias are great boats but the don't offer all the features we are looking for in our custom Distant Shores cruising yacht. Thanks for your comment.

[@richardmondio7216]

Solution: Get a 100-foot yacht - all your problems solved...

[@DistantShoresTV]

A 100-foot yacht solves many problems, Richard! 😊

[@richardmondio7216]

@@DistantShoresTV Perhaps, you could do a raffle ticket to raise funds for your next yacht and the winner will come for a ride with you in the Bahama's Great Exumas (Hint: that beautiful place you parked your boat in those shallow waters where humans depart to go to heaven🥰).

[@jamescapstick916]

you have all these options ,why change, bear in mind the corosion problems, always a worry, iam speaking from having sailed for 8 years on my own alu boat.

[@DistantShoresTV]

Interesting 🤔 what kind of alu boat did you have?

[@BobbieGWhiz]

“Have you ever dreamed of designing and building your own custom boat? No.

[@Andy_M986]

Yes,for years it's been a dream,and it's going to happen,more than likely a Catamaran.

[@dollarette]

Lol, same

[@patappleton6285]

No, but if ever someone hits me with a magic wand that makes me an instant naval architect and I can gain a decades worth of boat building experience overnight, and I also just happen to stumble onto half a million bucks or so to do such a thing without then thinking of a lot better things to spend with the surprise gift of half a million bucks then yeah bring it on man !

[@dollarette]

@@patappleton6285 that's true, I love design

[@patappleton6285]

@@dollarette I love design too but it don't like me. I've been trying to sketch out ideas for refitting my yacht's interior but I have no eye for perspective or scale .

[@stevenr8606]

I am still sorting out why I careless about the concerns that Sheryl makes/says.