Kristian Ferrell
Designing and building an aluminum boat is a challenging but rewarding endeavour. It requires a high level of skill and knowledge of the specific grades of aluminum and welding techniques suitable for boat building. Online companies like Metalbaotkits.com offer downloadable designs to build at home, which can be paired with CNC cutting services from companies like CJM Technologies. Before beginning construction, it is important to select an appropriate design, such as the Adventure 12 or 16, and set up a jig and sawhorses to ensure a level and stable building process.
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What You'll Learn
Selecting the right aluminium grade
Aluminium boats are not made with just any aluminium. The type of aluminium you need is marked by grades, specifically either 5086 or 5083. It is important to look at what your designer specifies and ensure that your metal supplier is aware of the grade you require.
In general, the 5xxx series of aluminium contains magnesium. This gives the metal a higher tensile strength without the need for heat treatment, while still allowing for excellent workability and welding. It is also important that you use an appropriate filler material. 5356 was specifically designed to work with 5000 series metal and should be used when welding either 5086 or 5083 aluminium.
When selecting the right aluminium grade, you should also consider the cutting method. After purchasing your design files, you will need to contract someone to cut the material for you. There are a few options available, including laser-cutting, waterjet cutting, and router table cutting. The availability in your local area will likely dictate this choice. However, it is important to keep in mind the limitations and downsides of each option. For example, laser-cutting is limited by the size of the table, waterjet cutting leaves sand particles in the surface of the weld, and router tables have detailed cutting limitations.
Finally, consider the welding process you will be using. Avoid using a TIG welder, as it will warp and distort your boat. Instead, opt for a pulse mig welder, which is the preferred choice of professional boat builders. If a pulse mig machine is not an option, you can use a spool gun for your welding machine, but exceptional welding skills are required. Practice your welding techniques beforehand to avoid burning through the aluminium.
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Choosing the right cutting method
When it comes to choosing the right cutting method for your aluminium boat, there are a few factors to consider. The most popular methods are laser-cutting, waterjet cutting, and router cutting. Here's a breakdown of each method to help you decide:
Laser-cutting: The limiting factor with laser-cutting is not the speed or quality, but the size of the table. Many companies may not be able to accommodate larger designs. For example, a 5'x20' sheet of aluminium would require a large router. Laser-cutting is ideal if your design fits within the table size, as it offers both speed and quality.
Waterjet cutting: Waterjet cutting is a good option, and many shops have machines large enough to cut your parts. However, the downside is the edge preparation. Waterjet cutting leaves sand particles on the surface of the weld, which will need to be ground before welding.
Router cutting: This method is commonly used for boat building due to the availability of large tables and the absence of edge preparation. The downside is that detailed cutting is limited by the size of the end mill being used. However, as most boat designs are created with a CNC router, this usually isn't an issue unless there is an operator error.
In addition to these three methods, you may also come across CNC (Computer Numerical Control) cutting. This method is widely used and can be applied to various materials, including aluminium. Companies like CJM Technologies specialise in CNC boat kits and can fully cut your kit and form all parts to your specifications.
When deciding on a cutting method, consider the availability of services in your local area, the size and complexity of your design, and the level of detail required. Remember that each method has its advantages and limitations, so choose the one that best suits your specific needs and requirements.
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Welding techniques
Aluminium boats have gained popularity in recent years due to their durability, sturdiness, and affordability. However, they do require specific maintenance and repair techniques, especially when it comes to welding. Here are some welding techniques and considerations to keep in mind when designing an aluminium boat:
- Oxyacetylene, oxy-MAPP gas, or oxy-propane welding: This is the preferred method for repairing aluminium boats as it ensures a durable and permanent fix. Aluminium dissipates heat quickly, and these welding methods provide the necessary heat input for effective repairs.
- Use of Super Alloy 5: Super Alloy 5 is a brazing rod that can be used with an oxyacetylene torch to create a strong metal-to-metal bond. It has a bonding strength of 30,000 psi and is easy for beginners to use.
- Preparation and cleaning: Before welding, it is important to clean the aluminium surface to remove any oxide layer or contaminants. This can be done by stainless brushing or using a solvent to clean off any oil or dirt.
- Technique comparison: TIG welding provides greater control and is suitable for pretty handrail welds and fuel tanks. However, it is slow and puts more heat into the aluminium, leading to more warpage. MIG welding, on the other hand, is faster and more suitable for thicker sheets, but it may not be as controllable for fine welds.
- Practice and experience: Welding aluminium boats can be challenging, and it is recommended to gain experience before attempting repairs. Practising on scrap pieces can help improve your technique and understanding of the material's properties.
- Rivets and sealant: For those without welding experience, using rivets and sealant can be a viable alternative to welding. This method may not be as strong as welding but can still create a durable boat.
- Brazing: Aluminium brazing is another option that is easier and cheaper than welding, providing stronger bonds than rivets.
- Welding equipment: Consider investing in the right welding equipment, such as a spool gun for MIG welding, to ensure successful aluminium boat repairs.
- Pulsed-spray MIG: This technique allows for more control when welding thin aluminium sheets and can be used for repairs that require varying levels of heat input.
- Weldout percentage: Keep in mind that weldout, or the actual welding process, is a relatively low percentage of the total boat-building time. Most of the work involves cutting and fitting.
- Contamination management: TIG welding allows for better control in managing contamination in the weld pool. With MIG welding, it can be challenging to remove contaminants and may require extensive body work after welding.
- Hull construction: Most small aluminium boats under 20 feet are riveted, while welded hulls are more common in larger boats. When repairing riveted boats, welding may not be successful, and it is better to tighten rivets or use sealants.
These welding techniques and considerations will help guide your design process for an aluminium boat, ensuring that repairs and maintenance can be effectively carried out when needed.
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Setting up the jig
It's important to think about where you will build your boat. Consider how you will flip the boat over after welding. I built a custom A-frame to assist in flipping the boat and loading it onto my trailer after the build. Another factor is the location of welders and equipment. You need sufficient room to work, flip the hull, and load it onto a trailer after completion. Our 16' boat weighed over 600 lbs when it was finished, so it's important to consider all steps of the building process before bolting the jig to the ground.
It's critical that you anchor your sawhorse to the concrete floor. This is key, as you will be using hydraulic jacks later to form the bow of your boat. It's also very important that the jig doesn't move or shift during the build. I used flush-mounted concrete drop-in anchors to eliminate the tripping hazard of studs. First, pre-position your sawhorses and jig, then drill and anchor after completing the following steps for alignment and levelling.
Here's a step-by-step guide for proper levelling and alignment:
- Bolt the jig to the frame using angle iron and 1/4" bolts
- Square and centre your jig in your shop, accounting for the full length and width of the finished boat
- Cross-square the jig from the points shown. Adjust the sawhorse until both numbers are the same. It's best to work with a partner to ensure your tape measure lands in the exact location on both sides. Take your time to get the cross square as accurate as possible
- Drill your anchoring holes in one sawhorse only, and install threaded rods with levelling nuts
- Pull the other sawhorse tight, cross-square the jig again, and anchor the last sawhorse
- Use a laser to level all corners of the jig
- Check the jig for plum using the laser
- Tighten your locking nuts
- Double-check cross square, level, and plum, and adjust if needed
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Boat flipping and loading
When flipping a boat, it is important to have the right equipment and to take the necessary precautions to ensure the process goes smoothly. In the case of a boat builder in Maine, a special gathering of around 100 students was organised to flip the boats they were building. Each person grabbed hold of the boat somewhere around it and together they tilted and flipped the boats over.
For those without a large group of people to help, it is possible to flip a boat single-handedly, but it requires careful preparation and the right equipment. In the case of a boat builder at Ashley River Boatworks, the process began by building three cradles to hold the boat in position once it was upright. The builder then suspended a 2-inch black iron pipe between two gantry cranes with a couple of bearings and a couple of 4-inch load straps (the kind used by truckers to tie down loads on a flatbed) to roll the boat.
The next step is to lift the boat and remove all bracing and legs. Then, cut off the legs below the level of the cradles. The tricky part is when gravity takes over and the boat wants to roll sideways. It is important not to let the boat get away and to ensure it is high enough so it won't hit anything underneath. A load strap can be used to control the boat and ease it down.
Finally, the boat can be lifted into a full upright position and lowered onto a prop along one of the gunwales. It is helpful to have a few people on hand to assist with lifting the boat into an upright position.
Regarding loading, it is important to note that power loading, which is the use of a boat motor to load and unload a boat onto and off a trailer, can damage your boat, motor, trailer, and the launch ramp and lakebed. It can cause erosion and create hazardous holes and mounds that can damage boats and equipment. Therefore, it is recommended to use a trailer winch instead of power loading to load and unload your boat.
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Frequently asked questions
One of the first steps in designing an aluminum boat is setting up the jig. Boat hulls are constructed in a variety of ways, but for this answer, we will focus on a design from MetalBoatKits.com. This design uses a similar jig and setup process for both the Adventure 12 and Adventure 16 boats.
A jig is a type of tool used to control the location and motion of another tool. In boat building, the jig is used to ensure the boat is level during construction. Setting up the jig involves anchoring it to the concrete floor and ensuring it is completely square and unable to move or shift.
The aluminum you want is marked by grades, either 5086 or 5083. It is important to ensure your metal supplier is aware of the grade you require and that it matches your designer's specifications.
