Building an Aluminum Expedition Catamaran from SCRATCH! - PART 1

[@svdelos]

Part 1 of our boat build is finally heeeeeere 🥳 We are so incredibly excited to share this wild new adventure with you! If you can't get enough of all things Delos 2.0, consider joining on Inner Tribe on Patreon. Besides getting to watch all our videos one week early and ad free, you will also get all the inside scoop on the build, exclusive bonus content, invites to meetups and milestones in the boat build, direct messaging with us, and more! Visit patreon.com/svdelos and watch next week's episode right now!

[@1DVSB]

Such a great idea for a world cruiser. I remember seeing really big aluminum catamarans made for longline commercial fishing in Australia.

[@SailingSVPipedream]

I built my Trimaran out of steel (an ex steel chimney that is) many years ago now. It is nice having the extra strength or ability to deform rather than hole that an Alu or steel boat gives. I hit a rock a couple of years ago and it was a scratch and a laughing matter rather than a crisis. If I were building now, I would use Alu too. Quite like TIG welding Alu, the surface tension makes for pretty welds. Another cool thing I like about metal is just welding stuff on rather than using bolts and sealant. Great to get rid of all those joints. Anyway good luck!

[@me2onthenet]

WOW still vaccinating???

[@EvilTwinTT]

@@me2onthenet not for covid... It would be for diphtheria, tetanus, whooping cough, polio, hep A etc - same as most countries...

[@steburdekin]

Hey love the updates awesome you are living the dream 🙏 have you had any thoughts on grounding your masts on this awesome dream boat your building? 😍✌️

[@Shawn-wt4kh]

This video really highlights one of the unheralded strengths of the Delos KZbin channel: storytelling. I've been lost when watching so many boat builds. But this video tells the story from the big picture to the little details. It's perfect.

[@ramilbautista4573]

and super educational

[@svdelos]

Thanks so much Shawn! We're still getting the hang of putting these videos together as they are quite different from our usual sailing episodes, so glad to hear that you found it clear and informative :)

[@jib9458]

i aagree, very strong

[@wronganswerswoody]

Absolutely agree. I'm usually not a fan of endless boat work episodes, but this one kept focused from start to finish (apart from the usual promo bit). A master-class in story telling and editing 👌

[@justinromer6128]

This is so true, the best part about this team is the story telling. Story telling is quite often undervalued compared to shock and awe or anticipation for a thumb nail to be solved. But it’s what has kept us watching. This new part of the journey is going to intrigue all of us and get us sucked right back in to the anticipation of the next episode.

[@GNelson1989]

I love how Dan acts like the typical boilermaker, talk trash and get the job done! This build is amazing!

[@Youtuber-k2p]

Trash is American, we talk garbage. 😅

[@thomas5714]

The quality of this video makes Hollywood look anemic. The content, editing, graphics, photography, sound track, everything is just spectacular.

[@svdelos]

Wow thanks so much for the kind words Thomas, so glad you're loving the videos! It's been a bit of a different beast trying to film and put these ones together, so it's great to hear that we're on the right track!

[@gsabo1000]

There is no Hollywood any longer.

[@davidwheeler7503]

​@gsabo1000 yes, it's become Hollyweird or Hellwood

[@Biomirth]

@@svdelos You're not on the right track. You are the right track! As far as filming and storytelling and editing, there is nothing better than this one guys.

[@stingb6983]

When does AG1 go away? Love you guys and all but never want to hear about AG1 again!

[@xpresident]

I’ve worked with metal fabricators for 30 years and those boys down under are real pros! Good luck!

[@artd4374]

I was a bit surprised to see aluminium being welded with MIG. Fast, yes, but is it as strong as TIG welded joints would be?

[@jagababa]

It's incredible how precise they seem to work!

[@dw3460]

​@@artd4374 tig is too slow, have more gas issues and puts too much heat into the material. A properly set up mig does a fantastic job.

[@artd4374]

@dw3460 which type of welding is used on critical projects such as nuclear boilers and aircraft? I always assumed TIG would be used. The amount of heat is dependent on machine settings and the skill of the operator.

[@dw3460]

@@artd4374 I did my trade building boats not far from where this video was taken. So my knowledge is limited to boats and general aluminum fabrication. There's no way you can lay down weld quick enough with tig in comparison to mig. Welding aluminum needs to be done with a hot weld moving as quickly as practical. You still get a full penetration weld. But it also minimizes the heat build up in the material. With a MiG welding flat out a roll of wire will see your day out. Even if you are quick with a Tig you will be stopping every couple of minutes to pick up another filler rod. Weld with a pulse MiG as most do now and you have a lot of control over the process and weld parameters.

[@esmith1771]

As Brian said, "It's mind blowing!" It really is mind blowing!! Such an amazing, exciting project. Thank you for taking us along.

[@svdelos]

Thanks so much Elsie, glad we're not the only ones who think this boat and this project is soooo crazy (in a good way of course!)

[@nixer8984]

As great as Brian is as far as bought upkeep, troubleshooting (extraordinary), and overall great Master of Delos, he is going to have a huge leg up on 2.0. After all he's building it from the keel up, or in this case down! Loving it, thanks.

[@mikethompson2137]

It’s looking awesome guys!

[@huntakilla1234]

Aussies are just so chill. They don't take life too seriously, which is exactly my kind of people. 👍 Also, the amount of progress that you guys and the team have made is astonishing. 💪

[@svdelos]

The Aussies really do have such a great outlook on life don't they, such a joy to work with and all around Legends!

[@drain_001]

This build is going to be the best possible commercial for those blokes. Excited for you all.

[@2DLAKE2]

LET DAN KNOW… we the FANS love that he’s allowed the filming of his process to a small extent… pretty cool and very appreciative! 💯🔥

[@johnd7129]

I'm so proud of the progress you have made on these huge changes to your lives. You are worthy of adoption as honorary Australians during your build. You have also chosen a most attractive part of Queensland (I live about 60 miles north, on the Sunshine Coast). Welcome and good luck.

[@TheMrBrianh]

Worked at an Aerospace company laser welding electrical connectors into aluminum housings. Every part was washed in toluene, then acetone and finally methanol. Always found it interesting going into the washroom with all the nasty fumes, despite all the chemicals being in a ventilation hood.

[@wheresbrent]

Reset to Episode 1. This is truly a new chapter! Way to go Brian and Kazaa!

[@svdelos]

Oh yeah, not just a new season number but it's own numbers!

[@mtollmaster3747]

I’ve welded now for exactly 40 years and that amount of work still boggles my mind. Amazing

[@kooooter66]

I just love watching skilled tradesmen amazing welding skills.

[@svdelos]

It's something really special isn't it! We're learning so much from them and the progress is insane!

[@nakamakai5553]

As an iron-crafting and aluminum fabricator and multimedia welder with scores of spiral railings in my rear view, I really appreciate all the references Brian makes about things moving and shifting with heating and cooling. Necessary and sufficient clamping and tacking are a must, else it all goes haywire AF. There may be no way to recover without scrapping lots of work. I am very much liking this series, and agree that the principals really know what they are doing. Can't wait to see 2.0! Proud Delos fan of umpteen years.

[@rickwilson3032]

This is so awesome. Great to see the error in the plans and how your team solved it. You have the right guy running this amazing build.

[@svdelos]

Thanks Rick, we feel SO lucky we found Dan, him and his team have exceeded our expectations at every turn!

[@gordoncarlisle5672]

I've been following you for 10+ years and you have been talking about and planning this for so long. I'm so happy you are finally able to make this a reality. I can't wait to see the weekly progress!

[@Stikker021]

Life is realy bad when you have to wear UNDERWEAR! Heaven help us all. 😁 I am SO looking forward to this catamaran build. I am tired of watching folk build plastic boats. Looking forward to aluminium manufacturing for a change. Oh yea, Brian, you have to get used to saying AL-U-MIN-IUM now that you're in Oz. 👍👍

[@svdelos]

Finally some who gets me 😂The underwear struggle is real hahahaha. Glad you're stoked for the aluminum, and yes we'll see if I adopt the extra "I" by the end of it all!

[@rogerbayzand4455]

@@svdelos Don't worry you won't be in undies long, by September we will be heating up and by Christmas were cooking! I know getting settled takes a bit of sorting but the health system works really well here, we have lived all over the world and chose to settle in OZ because it was the best place we could find. If you want get away for a couple of days come up to Mooloolaba on the Sunshine Coast.

[@landahoy5217]

I can’t stand underwear 😮

[@SouthPostAustralia]

As an Aussie, we're so glad to welcome you to our country! Hope that you all love living here as much as we do. It's always better to be on the water, but hopefully, this will be a strong second best for you guys.

[@inscop520]

The cool thing about helping with the build is that you will know the ins and outs of your boat like no other person.

[@walterhiegel3020]

Wowow these guys are really good at building. You guys definitely hit a home run on the quality of workmanship. I can see that another helping hand is a real asset to the build team. I was wondering how helpful that you guys would be but they are so organized that you are definitely contributing lots to the build.

[@TheThreebucks]

So happy for all of you! What an exciting adventure for all of us! So satisfying to see Sierra have more room for her bicycle and you enjoying a huge fridge. ☺️

[@KIRALYW]

Dan & Kurt are representing the Australian spirit so well. Feel free to learn breakdancing fellas. 😆👍🏽 Absolutely ripping stuff to follow along & she’s being built right here in the land down under. ❤

[@dukx3986]

Thanks for sharing raygun with the world.

[@NapFloridian]

Wow, that is like building a model kit, unbelievable. I am so excited about the building of Delos 2.0

[@clivestainlesssteelwomble7665]

It's really interesting to contrast the skin on frame Al fabrication used here with the Shell first method being used on Odd life 2's build in France. There was a stage where steel and Al hulls were also explosively moulded 😬 a very rapid way of forming a hull without external welds but very hard to control and needing some complex metallurgy in the raw metal sheeting. Given it was used to form monohulls it might be easier to form the shallower hulls of a Catamaran 🤔.

[@svdelos]

It really is like putting a kit together in a way, just with a looooot of pieces and an extremely large instruction manual!

[@MegaKevboy]

Now I want a model kit of Delos

[@BillB23]

I've watched several channels transition from building to sailing content, with varying success. Here you are, doing it in reverse. Nailed it! I'm already jonesing for Ep. 2 and eagerly await the time when I can once more wish you fair winds and following seas.

[@svdelos]

Wow, thank you!

[@drain_001]

Uma's doing it too :)

[@BillB23]

@@drain_001 Theirs is a massive refit. M&J, on the other hand, seem to like building more than sailing.

[@bobbyalexander3160]

Delos has been inspiring me since they started. So much so that I sold everything and have lived onboard for 3 years now. Thank you Delos for the inspiration. We look forward to our paths crossing.❤❤❤❤

[@glencrandall7051]

It's amazing seeing the bare bones. There must be miles of welds to complete. One wonders how such a small crew can accomplish all that needs to be done in the time they have. The coming months will be most interesting as the build progresses. Thank you for sharing. Have a great day and stay safe.🙂🙂

[@robertlaird6746]

I love the way Ozzies talk. The words that they use is pretty cool!

[@svdelos]

We're going to do a little Ozzie Lingo segment in one of the future episodes 😂 so many great sayings that we just love

[@robertlaird6746]

@@svdelos I'm looking forward to that!

[@paulstephens5229]

That’s how you do it. SV Delos style, sailing or building, you guys rock.

[@svdelos]

Thanks so much Paul, stoked you're enjoying this new style of video!

[@lilygirl2719]

Looks like a really professional boat building group - with real craftsmen you do not see everyday. I hope they get a lot of exposure and work from this partnership.

[@flychip4001]

I am so excited for you all, looking forward to watching your dream come together.

[@svdelos]

Thanks so much, we're so stoked to have you come along for the ride with us!

[@webbstua]

Congratulations on the boat build! It’s beautiful! As a farmer/welder I get anxious seeing the wedding ring around a welder. I’ve seen current arc through the ring and it’s not good. Looking forward to seeing this come together and the adventures that will follow.

[@schwags1969]

Many take them off when in work mode, otherwise it is not a huge problem really.

[@byronnelson8463]

Be like your work mates, hearing protection! Good luck with the build.

[@klasandersson7522]

I´m so glad you two have the oppotunity to be part of the construction af Delos 2.0! I have worked metall for 30 years and a hands on with aluminium is a must for most to get to know the hows and whys of the material. And the satisfaction of being a part of your own boat is priceless, will make your life on board in the future so much sweeter!!! Will be sooooo good to see the boat being buildt and you learning new skills along the way! PS. You know you have done enough welding and hot works when you can stop using ovenmittens to get your cookies out of the oven! 😉

[@johnmalenchek6597]

I'm glad to see the pros you have doing the build. Doing it all yourself would be satisfying, but let's admit it beyond the skills of most of us. Great progress. Hang in there. It's got to be challenging.

[@ElviajedeBohemia]

INDREDIBLE GUYS! Loving this, you're setting the groundwork for our life! Right now we are on the building the baby and living on a bigger boat phase!

[@robertbeger4275]

OMG I love watching master craftsmen do a job! I wasn't sure watching the boat build was going to be so fun but man it's got me glued to the screen. Getting more excited for you guys every day. Hugs!

[@tarivard]

just full of positive vibes! smile 24/7

[@tmgreenawalt9554]

I love that you all are taking us along for the ride. Watching you all adapt to living on land after watching all the amazing places you have visited makes me really feel for you all, especially putting Sierra in day school..ugh stressful. Love you all work like a fine oiled machine ..you will do great

[@richardclark8262]

OMG what an undertaking you definitely have the right man for the job good luck guys

[@alanwest4902]

One of the BEST boat build videos I have ever seen! Looking forward to seeing them all. Long live aluminuim!

[@dizzystick9]

This is fantastic I am loving the fact that you are sharing the detail that you are. I was hoping we could come along with you during the build and land life. Love it! Y'all rock!!!

[@jimborainbird2311]

Very excited to follow this project. Having watched Leo build Tally Ho out of wood over many years, I'm soooo looking forward to watching you build with Aluminum. Best of luck guys

[@leehoffman3604]

Great video. Exciting project. One of the best parts of the video was your outro. Sierra finally has cement to ride her bike, which I've been looking at in your vlogs for a long, long time, LOL. Have fun, guys. I look forward to next week.

[@SR-kf4yf]

Thanks for sharing the adventures over all these years. Excited for you all as you tackle this new challenge.

[@teddyturman5228]

Outstanding start to the build series! Can't wait to see them all,

[@Halespeed]

I never thought I would see Brian mowing the grass.

[@marcellacruser951]

I spent a couple months swamping for a welder. Every time your guy starts, I instinctively glance away from my phone. LOL

[@BrianMorin-t3c]

Brian and Kazza life is truly amazing for your family and thank you for bringing me along!! Delis 2.0 is going to be a beautiful sailing cat and your travels will show the differences. Between monohull and cat vessels. I predict another wave of sea lovers being born.

[@alebeda]

Amazing! 🎉🎉 so happy to be following along on this build!

[@papajeff5486]

Land life…adjusting…I have no experience…maybe a little. I would come home after a deployment overseas, in a hectic war time hustle, busy and extraordinarily quiet, compared to home life. Home life adjustment was, not only new points of responsibility, but, also a huge increase in points of stimulation, all at once. My wife was an in home patient angel/miracle, helping me adjust. I can just barely imagine adjusting to land life after years of living on the water, whewwww. Good on you, adjusting to land life, helping Sierra’s adjustment and YOUR NEW BOAT BUILD. May God be with you. Thank you for sharing your life with us…from the US, east Tennessee.

[@georgeramsay7030]

So wonderful to see D2.0 rising! Sierra in Skool, a big fridge, real beds and showers❤. Please talk more about the interior designs, engine rooms, water makers etc. INFRASTRUCTURE!!🍻🍻🍻

[@svdelos]

Glad you enjoyed this one George! We've got Sierras first day of school, engine mounts and rudder tubes coming at ya next week, plus a slightly unconventional destruction test of aluminum vs fiberglass!

[@red-doggracing5557]

I’ve been watching you guys for over 10 years so it’s cool to see the new boat been watching win your brother was on board very cool

[@johnmajewski1065]

Two Very Brave hearts ❤ awesome to jump into the deep end to tackle an epic adventure in boat building your own Delos 2.0 29:08 welcome to Australian way of life! SV Skoiern lV

[@garybaker6548]

Holy cow...Brian mowing a lawn! I think I felt the earth sift a bit on its axis. Seriously, the video was great. As others have stated, your production quality is as professional as it gets. Thanks for taking us along on this adventure. Hopefully the adjustment to land life (and lawn care) will get easier. You three really are a joy to watch.

[@Denkar11]

Fascinating to watch this boat take shape!

[@dougdean3134]

It’s great to Sierra actually ride her bike for real!

[@grantcourtney4916]

So excited about this new Delos chapter. Gonna be good.

[@aarongray3692]

Amazing! Love to see you’re able to be part of the build. What a great team to be working with.

[@Montego6500]

I just can't wait for this amazing ship to be floating and you are all partying it up and having a blast. Would be really cool one day to join but that I will have to reserve for the videos

[@murrat]

I'm blown away by the progress in the first episode.

[@waynesinkler6345]

I am amazed at how much fun it is going to be watching new build ❤😎

[@woodnymph79a]

I am so proud of you, and so happy for your sweet family. Been watching since the very beginning, and I couldn't wish more than every happiness for you lovely people. I'll be watching as Delos 2.0 unfolds, and as always, rooting for you special souls. Much love.

[@thepreparedpinoychannel]

Excited for the next chapter of your journey, Delos Fam! Cheers!

[@tyrondavids4287]

Amazing to have that feeling of pride that you were part of your boat building. ❤🇿🇦

[@paial]

Bryan, very nice project. Look into 48v electrical, specially "light hybrid" cars, come with great 48v alternators, 8kw+++, and cheap. If you fit a one or 2 one those in each engine, you have a hell of a "generator" to replenish the batteries (or work straight with a big inverter for big AC loads). Also a lot of on land off grid projects are 48v, so you find a lot of inexpensive equipment (solar chargers, inverters, etc)

[@americanrider]

The Tesla Cybertruck has a 48v electrical architecture, might want to look into researching it's engineering and execution

[@sunjun222]

These guys are there best advertisement. Super qualified and I bet watching these videos they get lot of new builds.

[@edl617]

Extremely excited for you and a wee bit jealous

[@JefferyYoung-j8t]

Awesome,that's cool you boys are doing a beautiful job Brian looks like you chose some very talented fabricators!!!!

[@MikeV607]

Awesome...can't wait to see the progress and the splash. 👍😊

[@jeffwhitelock1013]

I'm glad you guys are able to live your dream while living you dream!

[@janzuidam2892]

Just after 3 pm and still at work (close to Amsterdam, the Netherlands). Not busy at all so time for Delos 2.0 and loving it. What a change in life it is but you are all doïng wonderful, keep it up and I follow along.

[@wafula-dev]

Professionalism + Craftmanship💯

[@timom115]

It's amazing to see the process of building Delos 2.0, gives us a lot of perspective while considering buying or building our next boat!

[@gsabo1000]

I am so excited for all of you. Bigger boat means bigger family!!!

[@zaffora]

They designed a flat-pack sailing yacht, amazing!

[@Biomirth]

Ikea, eat your heart out :)

[@BajaGirl302]

This is right up my husbands alley!!! He is a master fabricator!! The best!!! And there isn’t anything he cannot do!! ❤

[@gardenrailroading]

The only constant in life is, Change! Love you guys! Laissez les bons temps rouler!!

[@svdelos]

Bien Sur! Sending lots of love right back at ya!

[@Audra-littledipper]

I don't know if this will get read, y'all are so popular! But, I have to say it... Dear Kaz, Thank you so much. I saw the ag1 adverts all over the sailing channels, but it was you that convinced me to try it. My stomach has always given me trouble. I have ankylosing spondylitis and I live life with great pain. This disease also attacks my gut. I ordered the starter pack without realized that it needed to refrigerated (y'all should mention that more). It seemed to still provide me with great benefits but it was making my tummy issues worse. But the travel packs were great, so I snagged a box of those. An expensive experiment! It was all worth it. AG1 makes me feel human again! I would never have had the courage to spend so much money if you hadn't talked about it helping your gut health so much. Tack så mycket! Wishing you and your family the best on your new adventures! ❤

[@muravi8167]

Fantastic ! since 2014 following you guys, was most excited this vlog looking at Delos 2.0 taking shape. Loved the vlog.

[@svdelos]

Oh wow 10 years on the adventure with us, that's awesome thanks so much for sharing in this journey with us!

[@linn6980]

So fascinating, the aluminum fabrication and framework assembly. Amazing technology.

[@jeffd4554]

I have been waiting MONTHS for the Delos 2.0 build!

[@svdelos]

Yessss we are so excited to start sharing this series with you!

[@Unfunkification]

I am so excited for you all, it’s got to be a highlight to be able to help build your new sailboat.

[@Valerie_Dawn]

Very funny to see Brian playing a boat welding game of Simon Says. This is going to be a sweet vessel.

[@frankg4668]

I swear these videos keep getting better and better! Love watching your journey and the making of Delos 2.0! Thanks for taking us along 👊🏽

[@Kalmanovitch]

Whoo Hoo !!! Let’s get building !!!🎉

[@CaptainKseadog1]

I am over the top with excitement for this build. Living the Land Lubber life has it's drawbacks....like mowing the lawn. YOU GUYS ROCK!❤❤❤

[@MrPaulcm1]

Amazing, reminds me of the airfix kits as a kid lol. What a great journey ahead, wonderful people. Yay.... so exciting. Love the vlog :)

[@josephle979]

What a dream! I am so pumped to see and follow you guys for years to come on this beauty. You have taught me so much just from watching your channel over last year fews. When I first heart of a yacht made out of aluminum I thought... what about lighting storms? And then I looked it up and learnt about the Faraday cage principal. I looked up Catamaran designs as well. It looks like you will have so much more space and functionality to cruise the vast oceans.

[@nikolaris2636]

Finally!! I have been waiting for this episode for months 🔱🏴‍☠⛵

[@crabbyhayes1076]

I really enjoyed this video. It appears you have assembled a great team; and already seem to be working well together. Working with people who can quickly discover problems, make decisions, and fix them is so important. Good luck to you

[@S.L-Sully]

IT'S FRIDAAAYY DELOS TRIBE!!!

[@svdelos]

Yessssss 🙌 happy Friday!

[@jenniferbyrd1970]

Wow. What a process. I’m so excited to see her journey. So happy for you guys. ❤

[@claverton]

Hope you settle in well and enjoy your time here. Sorry about our daycare bureaucracy ... hope you were eventually able to navigate through that cluster f...!

[@frodosadventures8757]

After following you guys for years, My 11 year old daughter has just started to take an interest in watching your videos! A few times lately, she has asked " I'd there a new Delos video out yet" we Chromecast it onto the TV, and we sit there having discussion about what's going on, boats, sailing, the places that you are exploring and funny things that Sierra sais and does. It's soooo cool!

[@brucemckelvy9920]

What an incredible design and build technique. Will be a lot of fun to watch it come to fruition.

[@chrisdesselles4441]

So cool... Beats the heck out of the hassles of Fiberglas construction.

[@ericd7975]

This channel is so much fun and the boat build is sensational. I can’t wait for next weeks instalment

[@OcRefrig]

Great video ! Are u Going to Leave the Aluminum Raw , Paint it or Powder coated for Bullet proofness. i'd Recommend - Powder coating the inside of the Hulls for sure. Especially Storage areas. Power coating is Bullet proof ( not literally) , Resistant to acid and tough as hell , won't chip off even if you bend the metal , totally seals the area so nothing can permeate it. Pretty incredible stuff. Epoxy powder coating is resistant to acid.

[@rickhunt4487]

I am SO HAPPY 4 yall ❤