Building an Aluminum Sailboat Pt 5 - How to Weld an Aluminum Sailboat | EP 223

[@hershbagelstein545]

I can see why it really pays to get the best boatbuilder/engineering team you can afford. The attention to detail, to meet international safety standards and to do so on a reasonable schedule is impressive.

[@rhonin210]

This is an amazing series! i love it.

[@j121212100]

aluminum boat is probably the safest boat. particularly when it comes to collisions with rocks. lookin good

[@gregzeszotarski9927]

Very interesting, I was a mechanical engineer and designed an aluminum electronics enclosure for a navy shipboard auxiliary propulsion system. The problem we ran into with aluminum is the mid section of the enclosure had a tendency to bulge in relation to the top and the bottom. Aluminum welding and maintaining it to spec is truly an art. Probably should have the cabinets built in the Netherlands, they obviously have the experience. Incredible work.

[@Cptnbond]

Thanks for documenting the process. You have for sure selected a very skilled builder for your dreamboat. I enjoy this in depth episodes. Please continue with these. Cheers.

[@DavidBrown-tt2lm]

Well wow! The Naval destroyer I was stationed on went through extensive overhaul in the Portsmouth (US) Naval Shipyard where the best welders in the world work. The aluminum welds on your boat are every bit as beautiful as anything out of Portsmouth. The testing and inspection philosophies and techniques used on the Orion are first rate! I’m very excited for you both and look forward to a future opportunity for a “Sail Away”! OK, one note: What I think is Paul’s collar-mic would look so snazzy if modified slightly to look like a bow-tie.

[@DistantShoresTV]

Thanks for this wonderful feedback, David! Sheryl said the same thing about my mic looking like a bow tie. 😂

[@Chris-fo8wp]

The Dutch are absolutely artists at metal boat building!!

[@icarium6031]

Best welders in the world? How do you know this?

[@normanboyes4983]

@@icarium6031It’s an American perspective - like the World Series.😉

[@mickramsay5002]

Hey Paul and Sheryll, thank you for answering my request regarding the welds. I have watched the last years how Tally Hoe and Acorn to Arabella were constructed, 2 phantstic wooden boats. But to be honest,an aluminium-boat is a very sexy thing too. Interesting is especially the short building time. Can‘t wait for more episodes.

[@SuperFebras]

Thanks for sharing this journey with us. Greetings from Bradford, just south of the marvelous Lake Simcoe in beautiful Ontario one of thousands belonging to the people of this vast and great country, Canada. " Que bonita barca-a-vela" is what a Portuguese like me says about this boat. Obrigado.

[@DistantShoresTV]

Obrigado!

[@mp6756]

Wow what a strong structure and the workmanship is amazing.

[@DistantShoresTV]

Thanks Mike! Yes we’re happy with the work done so far

[@erichamilton5932]

The Dutch have some of the finest craftsmen around.

[@YTMegiddo]

That is amazing! But it looks like doing that tedious might lead to lots of issues. But apparently not! Gorgeous work.

[@geezenslaw]

Paul & Sheryl...! Simply overwhelming #5...! I can't imagen what could compromise that hull with the exception of sea water... I hope you do tour with the cathodic protection of so much metal...! Fair Winds...

[@DistantShoresTV]

Thanks Captain Ron! I'm glad you're enjoying the series! We are planning an episode devote entirely to managing corrosion on board. It is important for all boats whatever the hull material and often overlooked.

[@davidc6510]

Looking Great! Thanks for sharing.

[@dougmarder]

I always wanted to see this being done, and thank you for going into some detail on the weld inspection process! The next steps are sure to be just as interesting. Please try to walk us through the tankage, electrical and plumbing install, as well as how they deal with dissimilar metals, especially those going into sealed, non-observable spaces. Looking forward to running into you again in Annapolis!

[@DistantShoresTV]

Thanks Doug! We re working on detail in-depth videos on electrical and power and other systems in upcoming videos. See you at the Annapolis show!

[@realestatevideographyllc1744]

So many welds, and the preciseness is impressive!

[@taterkaze9428]

Beautiful design and engineering. Three-month build is impressive. Short build time must improve quality by keeping a single build crew continuously engaged.

[@Tomm9y]

Fascinating work. I had no idea of the meticulous methods for this type of aluminium boat building.

[@williamlongyard5887]

Hi Paul. We spoke at Annapolis where I asked what type of MIG welder your builders used. I speculated it might be a pulse MIG, a relatively new and fare type. You said you would enquire. Thanks.

[@DistantShoresTV]

Looking at our video I see the machine is made by Fronius and appears to be a TransPulsSynergy machine so I suppose you are correct from the name it is a pulse machine :-)

[@williamlongyard5887]

@@DistantShoresTV I've got to get a bigger screen so I can see that! Thanks. I've written several books that touch on aluminum fabrication and I have to say that this welding is very impressive. I really enjoy the technical details you present, but also your videos on canal cruising. I've done a little of that in France on the Cher leading into the Loire. Bonne route!

[@saafan]

Really enjoying watching your videos & will be waiting for you in Egypt to visit the Red Sea 😍🙏

[@DistantShoresTV]

We loved our sailing visit to your amazing country back in 2006!! Hopefully we’ll get back soon❤️🇪🇬

[@darren5472]

I guess it's all about strength but only a few small windows in the hull. It will be interesting to see how light it is inside when it's finished. Can not wait

[@DH-le4ve]

Thanks for this series

[@LoanwordEggcorn]

That's beautiful and careful work!

[@davidzaharik5408]

Very cool ... a lot of memories of my build... would love to do it one more time!

[@markhwl8345]

Oh wow, what a journey. Keep going

[@gdholmfirth]

Thank you for uploading this and keeping us updated on the progress of our new boat.

[@waterboy8999]

The boat looks fantastic! What a piece of work.

[@scyz2807]

I love seeing the evolution of your boat. It's hard to imagine what it will be like when it's finished. But then, through computer graphics you've already seen it finished. But I'm sure you too are very excited to see the finished product. To learn to how she sails. I'll be attending the US Sailboat Show and expect I will see you there. : - )

[@DistantShoresTV]

Please say hello at the show👋

[@QImpact]

Looking good, much easier to get a feel for the finished yacht when it is upright. The upside-down walkthrough in the last episode was a bit challenging to visualize (maybe I should have turned my monitor over). One of my questions was answered here, I always wondered if the hull formed part of the tanks or if they sat on the hull - it looks like the former. Hope you include in an episode the installation of insulation, that is another thing I have wondered about aluminum yachts.

[@ZeffyZ]

Super graphics and explanation Paul. Looks professionally made, and makes everything so easy to understand and interesting to watch. This is a far cry from a lot of videos on here where it's camera in one hand and the other pointing a finger..

[@DistantShoresTV]

Thanks Zeffy! The graphics are fun to make but take a while so It’s great to hear they help😀

[@MrThing42]

I miss the travel and episodes, I can’t wait

[@rollinrock6696]

It’s huge!

[@hthring]

HUUUGE! It looks so good.

[@lancedias7261]

Another great episode in your build journey & nice to see the fast progress being made. If possible, it would be interesting to hear a comparison between some detailed aspects of the build between fiberglass vs aluminium.

[@DistantShoresTV]

That's the plan Lance!

[@bobsails9750]

Thank you

[@gayemeyer]

Mouth wide open in amazement!!! Such science too! P.S. Love Dave Brown's bowtie mic comment lolol!!

[@DistantShoresTV]

Thanks for the kind words Gaye!

[@2thelight]

Thanks for sharing, the hull thickness was incredible, you'll have no problem with icebergs :) An old salt once told me when asked about longevity of hull materials, "steel lasts 100 years, aluminum lasts 50 years and fiberglass lasts forever". That being said, I can see where aluminum could be lighter and faster, additionally I have seen a very old aluminum boat (which was painted) where the salt got under the paint and corroded a hole through the hull and required a huge amount of work. Do the boats that are not painted have the same problem?

[@LoanwordEggcorn]

Commercial Steel boats/ships have a design life of a few decades at most. Aluminum can last forever because when exposed to salt an oxide layer is formed, which is inert and protects the raw aluminum. (This process is called passivation, and the resulting layer is called anodized.) Plastic boats probably last forever. Consider how long the oil they're made from lasted in the ground. Aluminum is probably the most eco-friendly since it's so durable and is fully recyclable.

[@mz2288]

Amazing work. How many thru holes will the boat have? Can you reduce to one only?

[@jimj2683]

Some ideas for the new boat: PTZ camera mounted on the mast to give a perfect birds eye view when docking. Telescopic pylon that acts like a push-button anchor.

[@DistantShoresTV]

I like the mast camera idea as it would be great for docking.

[@jimj2683]

@@DistantShoresTV I first thought a tethered drone would be ideal, but I think drones are illegal in many places.

[@Quozl]

Great video as always. How do they clean the fine metal particles and slag created from the building & welding processes out of the hull and nooks and cranies before finishing the build and starting the interior fit out? Is it as simple as a powerful vacuum cleaner and someone spending days making sure they've got all the fine particles out or is there different process?

[@artyspost]

It would be great to know what welding equipment the welders use. Great work

[@andrewjames7616]

Thankyou 👍

[@corujariousa]

Impressive welding work. The boat is shaping up nicely. Congrats! I noticed the window openings on the hull seem small and just a few. Why didn't you decide to add more and larger windows?

[@AustinBoil]

Curious if you will be painting the hull? I know it's not required but they look so much better when painted.

[@jeanrusso3822]

so interesting to see how an aluminum sail boat is put together...thanks for documenting the process. Just curious, what is the price tag?

[@willags]

Hi how will it be insulated with spray type ?. Looks amazing I'm not jealous

[@rodhogg8858]

You’ve probably already covered this but what aluminium plate alloy and welding electrode designation are you using?

[@НиколайАлексеевич-в6к]

Электрод не плавится он из вольфрама, марку материала и присадочного прутка и режимы сварки ... Это есть ноу хау судоверфи. Никто не скажет. Это цеховая культура старой Европы, которую пытаются разрушить , но Английское колесо даже ЧПУ не берёт. 🎉

[@Mars_Life_and_Beings]

Amazing, I am an amateur welder and I can't get any aluminum welds to stick.

[@BarkTheAlliedGiant]

Do aluminum yachts fare better in lightning strikes due to electronics being almost fully enclosed in a metal shell (Faraday cage effect)? Super interesting to see how these vessels are made. This team of builders is really impressive!

[@Cacheola]

...and being one big metal lightning attractor out on the sea

[@simonhantler8062]

looking good guys. what thickness of insulation you going for?

[@DistantShoresTV]

Thanks Simon😊 we have 6cm insulation

[@seandenny1553]

Ballpark what are they cost for the different sizes and yours is a 49 but is there a 38 and a 44 or is everything custom?

[@VoyagesofNormanJames]

Hi Guys, I was a bit surprised that there was no extraction visible inside the hull. The Argon shield gas is much denser than air and would fill up the hull rapidly with potentially fatal consequences ! Was the extraction just removed for the video? It was great to see the competence testing that the welders undergo, I spent a considerable part of my working life certifying welders for aerospace work and the testing these guys are doing is quite similar - very reassuring 😎

[@LoanwordEggcorn]

The hull was welded with the hull upside down.

[@lutomson3496]

Surprised the have humans welding with machines much more precise

[@ZukoMbewu]

Just for interest's sake, why did they do staggered welds of the stringers to the hull? To reduce stresses on the metal, perhaps?

[@DistantShoresTV]

Thanks Zuko. The staggered welds reduce the stresses that can come from welding. Its similar to doing full welds on either side which make even support.

[@ZukoMbewu]

@@DistantShoresTV makes sense. Thanks. I am inspired by this build. It has me dreaming.

[@julieannecharters6132]

The stitch welds on the frames prevent too much heat input and shrinkage which would pull the plates over the frames creating a starved horse look which would look terrible.

[@MrThing42]

I feel like this is the longest build ever

[@DistantShoresTV]

This is actually very quick for a custom aluminum sailboat. It’s not like a production line of fibreglass boats built out of a mould.

[@felixtheswiss]

I just remember the pain to keep my welders up to the certification. ☺

[@bryanwatt9751]

It looks cavernous! How much does a boat like this cost?

[@greggbutler9344]

As least 1.5 million uk £ as a starting price for such a fine vessel like this

[@billowens861]

Nice work. I am surprised the foreman said it takes only three months to complete. I wonder how many man hours it takes them to complete this boat?

[@DistantShoresTV]

It’s 3 months for the aluminum work of the hull deck. Then a month in the paint shop before the fitting out begins …

[@frank1390]

Hi Paul, I just watched the video and looks like the boat is coming along great. I have a question. In the video you mention "the tanks". My question is for fuel or water? The reason I ask is that I have had a very bad experience with an aluminum water tank. If it is a water tank be very careful what you may put in it to clean it with. Or to keep the water fresh. !!!! All the best Keith Robinson SV Yolo

[@jamescapstick916]

do they resuage testing ?

[@LoanwordEggcorn]

All Aluminum scrap is recycled.

[@robsonvieira9027]

No Brasil construimos barcos de alumínio na garagem, quem quiser ver tem vídeo no KZbin veleiro lelei

[@Thomas..Anderson]

I wonder if anyone has tried laser welding for a hull?

[@andrewdavies4604]

Interesting that they prefer to weld from underneath. That would be a proper nightmare with welding steel.

[@DistantShoresTV]

Yes it means no debris lands in the area which might contaminate the welds...

[@НиколайАлексеевич-в6к]

4:13 " потолочный шов" свободный от шлаки и мусора за счет гравитации?? С поддувом инертным газом аргоном ( Аргонавты!!) мусора не будет , если культура производства как в этом цеху. Потолочные швы на сосудах ... Это высшая квалификация в любом виде сварки. 🎉🎉🎉

[@kurthoelter3495]

did i miss the explanation re ballast and keel?

[@LoanwordEggcorn]

I think it was mentioned in earlier episodes.

[@carbidegrd1]

looks like an airplane

[@LoanwordEggcorn]

Yes, airplanes have similar construction ideas, but the metal ones are mostly riveted instead of welded.

[@gianniskritikos695]

The dutch technician sould talk in his language, it would be more intresting.

[@propylaeen]

is 103.000 viewers really enough for financing this dream? how does all this work out or are your pockets just filled from som brilliant business before distant shore? The biggest mystery for me is mostly how does this all stay in flow.

[@DenCPen]

I cannot speak for them but I would say over 30 years of documenting their sailing experiences (pre KZbin) and good money management.

[@propylaeen]

@@DenCPen extremly good… I ran a company myself for 13 years in Germany with up to 28 employees paying salaries and insurance, having international clients… I crashed emotionally when my partner died but I have no Idea how to get the funding for such a big project in 2019 I had my eyes on a used Alubat 43 for € 49.000,- and yes it was stupid not to take her… but a newly build 49 at this standard hardly to get her in the water under sails for under € 650.000,- … don’t know how to get finance in the UK or elsewhere but here in Germany your over all assets have to quadruple your yacht investment if you don’t want your bank making jokes on your request.

[@DenCPen]

@@propylaeen sorry to hear about your partner and the turmoil that it caused. Hopefully another great opportunity will come along and you will be able to take advantage of it.

[@suleymansekman2697]

I prefer Single Helm and protected all weather like a Amel! Very Well protected cockpit! Maybe just like car or Van You can control window automatically up and down! Also well insulated and as possible as more solar! One more things toshiba's paperless WC toilet sistem! sorry I am just very amator sailer just watching and asking Why? maybe most of them not make sense ! Sorry.

[@annsheridan12]

Labor intensive, no wonder the price is so high.

[@LoanwordEggcorn]

Yes.

[@markdiephouse]

I can't figure out for the life of me why you would not incorporate a sugar scoop walk up transom ??? Please tell me why . Following seas ? Why, why, why ?