alu sailboat buliding

[zeyang]

here is fodder for you guys..

I got this question from a sailing forum.


>Do you have a welding sequence thought out?
>
>Jose


thats a good question.

i was thinking starting from top of boat as of today (along the keel) and work downwards in 1 meter sequence (then weld from 1 oclock to 2 oclock, go back to 11 oclock and weld to 12 oclock etc.) Maybe i should be more worried about distortion part but i have been welding quite a lot 4 mm without any distortion problems before and this is twice as thick.

im open for advice though.

zeyang

[zeyang]

finish 13th strake.

[zeyang]

2 more strakes left.



zeyang

[76GMC1500]

What are you going to fill the keel with for weight?

[zeyang]

Originally Posted by 76GMC1500

What are you going to fill the keel with for weight?

Some 5-6 tonns of lead ingots i think. (scrap lead)


zeyang

[76GMC1500]

Are you going to take any measures to isolate the lead from the aluminum or will you just seal off the area so it stays dry and electrolysis can't happen?

[zeyang]

Originally Posted by 76GMC1500

Are you going to take any measures to isolate the lead from the aluminum or will you just seal off the area so it stays dry and electrolysis can't happen?

Hi,
Will probably make it ingots (not seal off) and rather seal off the alloy (make a kind of fiberglass box inside the keel so i can easily take out the ingots if needed.

So in an emergency I can take out the ingots to make the boat lighter.

zeyang

[zeyang]

Plank 15 and 1 more to go. Had to cut whole in the floor to make space for this plank. Im spending my time thinking how to turn this 3 tonns beast around. Seems i have 2 options.

1. tear down the wall, move the boat out on wheels and turn it with a crane outside

2. move boat sideways close to wall, and turn it with 2 or 3 winches and make a kind of cradle on the out side of the hull first.

still a few weeks to think about this.




zeyang

[zeyang]

here are some interesting picture from a swedish guy turning his boat.

Sorry, its not directly related to welding but some welders might turn something heavy in future. who knows.

zeyang

[zeyang]

work on last plank. happy to see the end of this planking. its crazy timeconsuming work to get them straight and look nice.


zeyang

[TigWiz]

It'll all be worth it when you finally set sail. Keep up the good work!

[DavidSim]

This is a great thread, very interesting, I wish you all the best with your project.

Regards from Toronto, Ontario, Canada

[Nick Kent]

With smaller boats you can build two wheels that go around the boat. It can then be rolled over fairly easily. You would need quite large wheels.

[zeyang]

the bow touch the ground.


zeyang

[zeyang]

last plank is on. (#16) Just need a little work to get it fair and nice.

[76GMC1500]

Let me know when you bring that thing to San Francisco.

[jethro]

Have you considered not welding but using flush solid aluminum rivets ?
They would probably have to be at least 1/8 ir even 3/16 diammeter.
Would rivets seal the laps well enough ? Perhaps not enough presure on the joint ?

Never built a boat before.

[zeyang]

Originally Posted by jethro

Have you considered not welding but using flush solid aluminum rivets ?
They would probably have to be at least 1/8 ir even 3/16 diammeter.
Would rivets seal the laps well enough ? Perhaps not enough presure on the joint ?

Never built a boat before.

aviation industry use rivets, which make me always worried while flying :-)
but i think they manage to make it airtight due to thin alloy and glue or some adhesive in between.
Old boats also used rivets (huge clinker bolts) but i think that was due to lack of welding equipment. As of today i think maybe welding will be the easiest choice for 8 mm thickness.

but i would consider rivets when i start to make a dinghy or kayak.



zeyang

[76GMC1500]

I've seen how riveted joints are sealed. They form a lap joint, rivet it, then caulk it. The caulking process involves taking a round nosed drift and smashing the metal together in the lap joint. Very time consuming. Welding is better. Plus, there is no crevice corrosion.

[zeyang]

Working on re-inforcing the temporary frames to the hull by welding small alloy bits to the wood frame. When i flip the boat i will remove the wooden frame one by one, when i install the permanent alloy frame.

On outside i will make a square cradle in wood which will also be good to have to make the boat standing upright.



zeyang

[zeyang]

hi,
i wonder if someone know where i can find some portlights?
Im looking for this kind? They used to be made by a company called marine aluminum, but not now anymore.
zeyang

[76GMC1500]

You want Freeman Marine at www.freemanmarine.com We use their hatches on some of our boats, they're very good quality. Prepare to be shocked by the price, though.

[Donald Branscom]

All of the finished welding must be done on the inside of the boat FIRST!!!!

This is very important. Welds will shrink about 2% the length of each strake.

When you weld, start in the middle of the boat and work your way towards the ends. Back step your welds.
Make sure to weld on the port and starboard side at the same time. Do not weld up one side and then the other side!!! READ KLINGEL's Aluminum boat building book and you will have an expert for assistance. A must do.

[Donald Branscom]

Originally Posted by zeyang

aviation industry use rivets, which make me always worried while flying :-)
but i think they manage to make it airtight due to thin alloy and glue or some adhesive in between.
Old boats also used rivets (huge clinker bolts) but i think that was due to lack of welding equipment. As of today i think maybe welding will be the easiest choice for 8 mm thickness.

but i would consider rivets when i start to make a dinghy or kayak.



zeyang

Airplanes are riveted for strength because the parts are always moving around.
About three years ago the first welding tests to weld parts of a plane together were investigated. You can read about it in THE WELDING JOURNAL magazine.
They wanted to save the weight of all the rivets, but of coarse the aluminum HAZ is only 60% the strength of the parent metal. Steel is about 85% when TIG welded.

[Donald Branscom]

Originally Posted by zeyang

aviation industry use rivets, which make me always worried while flying :-)
but i think they manage to make it airtight due to thin alloy and glue or some adhesive in between.
Old boats also used rivets (huge clinker bolts) but i think that was due to lack of welding equipment. As of today i think maybe welding will be the easiest choice for 8 mm thickness.

but i would consider rivets when i start to make a dinghy or kayak.



zeyang

Airplanes that carry passengers do not put glue on the seams.
But the fuselage has an inner shell that is pressurized and is made of composite materials and is actually tank tested for air tightness. Look at the windows next tome you are in a commercial air liner and you will see there is a inner window and outer window.
There is a space in between.