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First appeared in slightly different form in Cruising World magazine, September 1997,
entitled "To Thine On Chines !e True"
Aluminum For Boats
Co"right ,--. - /00- Michael 1asten
Aluminum
is a sheet
material
)ith 2irtues
a"lent* To
honor them
best3 I
a42ocate
sim"licit3
am"le
5raming***
an4 es3
e2en single
chine hull
sha"es+
Why Build An Aluminum Boat?
'or things that go bum" in the night* 'or ease o5 construction* 'or longe2it* 'or goo4
resale 2alue* 'or the bene5it o5 being able to create a custom 4esign an4 buil4 it
economicall3 )ithout the huge "enalt o5 ha2ing to buil4 a mol4 5irst3 as )ith 5iberglass*
'or 5ree4om 5rom the stench o5 5iberglass3 an4 5rom the 4rea4 5iberglass boat "o6* 'or
re"air-abilit* 'or lightness an4 strength* 'or the com"etiti2e e4ge in "er5ormance* An4
most im"ortantl3 5or the securit o5 sa5e cruising*
http://www.kastenmarine.com/aluminum.htm
It takes o2er 703000 "oun4s "er s8uare inch 9"si: to tear a"art a chunk o5 mil4 steel3 an4
;03000 "si to 4e5orm the same "iece< to make it iel4* With aluminum3 aroun4 =>3000 "si
)ill tear it a"art3 an4 aroun4 ;>3000 "si )ill 4e5orm it* Yes3 ou rea4 that correctl? si@e 5or
si@e3 aluminum has a higher iel4 strength* In these 5acts lie the e6treme bene5its o5 metal
5or hull construction? The A"lastic rangeA o5 either metal is 8uite high3 so the material can
take a terri5ic beating )ithout 5ailure*
Aluminum is light3 strong3 corrosion-resistant3 non-s"arking an4 )el4able* Because
aluminum is not abrasion-resistant3 it can be cut )ith carbi4e tools* Aluminum is subCect to
electrolsis3 "itting an4 cre2ice corrosion3 but these liabilities can be manage4 as long as
the installation o5 4issimilar metals an4 electrical items are correctl 4one* A5ter that3 it is a
matter o5 atten4ing to these matters 4uring the li5e o5 the boat*
In terms o5 seakin4liness3 some boat sha"es ma be better i5 built in steel* AluminumDs
e6treme lightness can intro4uce a 5aster "itching an4 rolling motion in some hulls* 'or
e6am"le3 2er beam boats )ill e6hibit a gentler roll i5 built in steel* 'airl narro) or light-
4is"lacement boats3 )hich ten4 to ha2e a narro)er )ater"lane an4 less inherent 5orm
stabilit3 )ill bene5it most 5rom aluminum construction* These are o5 course
generali@ations* Gi2en a blank sheet to begin a 4esign3 the roll beha2ior )ill be consi4ere4
along )ith the choice o5 materials*
In terms o5 si@e3 one can success5ull buil4 a steel boat 5or coast)ise cruising an4 serious
blue-)ater sailing 4o)n to aroun4 ;0 5eet #OD* Belo) that3 the steel 2essel )ill either
ha2e to be built )ith e6cessi2e 4is"lacement or )ith 8uite thin "late that )ill be more
4i55icult to buil4 4ue to 4istortion )hile )el4ing*
An aluminum bare hull3 built to the same strength stan4ar43 )ill )eigh roughl =>E less
than the same hull in steel* As a result3 i5 high strength is o5 the highest "riorit3 the
aluminum boat can be built to the same structural )eight as the steel 2essel3 an4 then be
consi4erabl stronger*
We can there5ore create aluminum cruising boats 4o)n to3 sa3 // 5eet* One coul4 still
buil4 a sa5e aluminum boat in a si@e smaller than that3 but )hoD4 )ant to go to sea in itF

On Cost
The aluminum to buil4 a bare hull costs Cust un4er t)ice as much as the mil4 steel to buil4
the same 4esign* But aluminum is 5aster to )ork )ith3 so the sa2ings in labor hel"s e2en the
score* The labor sa2e4 can be substantial since aluminum can be cut )ith common
car"entr tools an4 is )el4e4 much 5aster than steel*
Another signi5icant a42antage )ith aluminum is that there is no nee4 to san4blast or "aint
the interior* You 4o ha2e to insulate an aluminum hull3 but that )onDt or4inaril re8uire
san4blasting* !ainting the e6terior o5 an aluminum boat is unnecessar3 re"resenting
another big sa2ings*
A5ter ouD2e 5actore4 in the a44e4 costs o5 "ainting steel3 the margin 5or buil4ing an
aluminum hull 4ro"s to being a 2er minor amount )hen com"are4 to buil4ing in steel* As
a "ercentage o5 the entire construction "roCect3 the a44itional cost o5 the aluminum becomes
2er slight in4ee4* Once built3 maintenance on an aluminum boat is less e6"ensi2e3 an4
resale 2alue higher* These 5actors more or less e2en the score bet)een the t)o materials*
(e) construction metho4s ha2e trimme4 metal hull buil4ing costs substantiall* The most
4ramatic sa2ings can be e55ecte4 b com"uter lo5ting3 an4 then com"uter cutting the actual
"arts 5or the hull* Gssentiall3 the buil4er recei2es a Aboat kitA rea4 5or assembl*
A "arallel metho43 also i4eall 4one b com"uter3 in2ol2es cutting an4 5itting the "late
onl3 b itsel53 )ithout a "rior su""ort structure*
One last note about cost? When com"aring like 5or like3 boat costs ten4s to 2ar more or
less 4irectl )ith 4is"lacement 9not length:3 assuming a gi2en le2el o5 com"le6it in the
4esign* Dis"lacement3 an4 there5ore cost3 2aries as the cube o5 the o2erall 4imensions*

On Hull Shape
Aesthetics are a "ersonal thing* 'or m o)n "art3 I am attracte4 to the single-chine sha"e
5or metal boats because metal is a 5lat-sheet material* When buil4ing a boat using sheet
material3 it makes the most sense to think in terms o5 that materialDs characteristics an4 ho)
one ma o"timi@e a hull 4esign )ithout incurring e6tra labor*
In metal3 a single-chine hull is easier an4 less costl to buil4 than one )ith ra4ius or
multi"le chines or one that is 5ull roun4e4* 'urther3 )ith a goo4 4esign there is no
"er5ormance "enalt )ith a single-chine hull* The slight gain in )ette4 sur5ace3 i5 an3 can
be o55set b slightl greater sail area3 ma4e "ossible b slightl greater abilit to carr sail
4ue to the 5orm stabilit "ro2i4e4 b the chine*
This line 4ra)ing
an4 the ones that
5ollo) 4emonstrate
4egrees o5 4esign
com"le6it 5or sheet
materials3 5rom
single chine to a
5ull roun4e4 hull* I
"re5er the sim"licit
an4 econom o5 a
single-chine metal
hull3 as sho)n here*
In m 2ie)3 it is a
more honest sha"e
5or a metal boat*
'urther3 the re"ute4 seakin4liness o5 a ra4ius-chine or roun4-bottom hull can be a""roache4
in a single-chine hull b gi2ing it a slightl more AslackA sha"e* A big a42antage o5 the
single-chine sha"e is econom< the cost to buil4 a roun4e4 or ra4ius-chine hull is
consi4erabl higher 4ue to the )ork in2ol2e4 )ith the a44e4 sha"ing an4 )el4ing*
A single chine can look 8uite a""ealing3 es"eciall )hen use4 )ith a more tra4itional
stle* In m 2ie)3 it makes the most sense to take an e6tra mone a2ailable an4 use this
to make a grace5ul single-chine boat longer rather than ra4ius chine or multi"le chine3
thereb netting some real s"ee4 an4 com5ort bene5itsH in other )or4s3 a bigger boat 5or
the same mone3 )ith inherentl greater s"ee4 "otential 4ue to the increase4 length*
Multi-chine
4esigns allo)
buil4ing )ith
5lat "late3
)ithout
re8uiring that
an "lates be
rolle4*
Although
consi4erabl
more time
consuming
than a sim"le
single chine3
these sha"es
remain )ithin
the
construction
realm o5 the
amateur or
one-o55
buil4er*

&a4ius-chine hulls
em"lo 5lat "anels
e2er)here e6ce"t
5or a narro)
Droun4e4D "late that
Coins to"si4e to
bottom3 ren4ering a
8uasi-roun4e4 hull
)ithout re8uiring
that e2er metal
sheet be rolle4< onl
those at the ra4ius*
Ho)e2er*** it )ill
al)as be
recogni@e4 as a
ra4ius chine 2essel3
an4 not a true
roun4e4 hull sha"e*
There5ore i5 a ra4ius
chine is being
consi4ere43 there is
2er little reason not
to sim"l take the
ne6t ste" an4 go to a
true rounded sha"e3
as 5ollo)s***

A 5ull-roun4e4
metal hull is beauti5ul
to behol4* The nee4
not be e6"ensi2e to
buil4 i5 correctl
4esigne43 )here onl
the minimum amount
o5 "lating nee4s to be
rolle4* These are not
Ara4ius chineA boats*
The are instea4 Cust
easil "late43
rounded hulls )ith
no re2erse cur2ature3
so these hulls can be
built economicall*
&a4ius-chine an4 multi-chine boats cost about the same amount to buil43 an4 a true
rounded hull - "ro2i4e4 itDs 4esigne4 correctl - nee4 not be an more time consuming nor
an more e6"ensi2e to buil4 than a multi-chine or ra4ius-chine sha"e* An4 as a 2er big
bonus*** it )ill look 2astl better+
It is generall our 5irst choice to make use o5 a single chine hull sha"e 5or metal boats* I5
5or some reason a chine sha"e is not 4esire43 )e nearl al)as 5in4 that a )ell-4esigne4
rounded hull is the ne6t best choice* It )ill share the same ease o5 construction as a multi-
chine or ra4ius chine 2essel3 but )ith a little bit o5 trans2erse cur2ature in the to"si4es an4
bottom*
Designing true roun4e4 metal hulls 5or ease o5 "lating is not at all 4i55icult* Our goal )ith a
roun4e4 metal hull is that the to"si4es an4 bottom )ill not re8uire an "re-5orming at all3
there being Cust enough cur2ature to s)eeten the a""earance3 but not so much as to re8uire
rolling* In other )or4s3 -0E or more o5 the 2essel is still able to be "late4 using 5lat sheets3
an4 )ithout an 5uss at all*
One e6cellent techni8ue )hen buil4ing a com"letel roun4e4 metal hull in2ol2es using
ACoggle4A "late seams3 akin to Ala" strakeA "lanking in )oo4* Accor4ing to this metho43 an
o55set is "resse4 in along one e4ge o5 the "late* The o55set is Cust enough to take the
thickness o5 the "late belo) it* Gach "late is a stri" about ,/ to ,I inches )i4e* Bernar4
MoitessierDs steel boat Joshua )as built that )a3 an4 it certainl )ithstoo4 the ultimate
test***+
Alternatel3 the "lating can be la""e4 b instea4 Cogging the 5rames to match the "late
contour* Just abo2e the la"3 the 5rame Cogs out to meet the "late abo2e3 etc* These la""e4
"late metho4s "ro2i4e a much easier 5it-u"3 an4 a much more easil achie2e4 )el4 seam* I5
Aline4 o55A nicel3 as one )oul4 4o )ith )oo4en "lanking3 the can also look 2er goo4*
The "late o2erla" creates its o)n longitu4inal stringer an4 rein5orcement*
With an o5 these t"es inclu4ing the 5ull roun4e4 metal hull3 as can be seen in each o5 the
e6am"les abo2e3 it is most economical in terms o5 labor i5 the keel is attache4 as an
a""en4age* In other )or4s gi2en the strength o5 metal3 there is no "articular nee4 to create
a large re2erse-cur2e4 garboar4 area merel 5or the sake o5 strength3 as )oul4 in4ee4 be the
case )ith a glass or )oo4en hull* This sa2es an enormous amount o5 construction time3 an4
is there5ore the most "ractical a""roach*

On "Frameless" Construction
With the notion o5 metalDs e6treme strength3 )e ha2e come to a "oint o5 5aith )hich has at
times create4 a misconce"tion? There is "otentiall mislea4ing an4 incorrect in5ormation
"an4ere4 b some in the im"lie4 "romise o5 A5ramelessA metal boats* The conce"t o5
5rameless metal boats is attracti2e3 but 5la)e4*
The 4e5inition o5 A5ramelessA must be clari5ie4H
Achie2ing the re8uire4 strength in a metal 2essel )ithout using 5raming im"oses an
enormous )eight "enalt 4ue to the re8uire4 increase in "late thickness* I5 one a""lies
)ell-"ro2en engineering "rinci"les to the "roblem3 one 8uickl 4isco2ers that 5rames are
sim"l a re8uirement* Designers ma em"lo 4e2ious strategies3 such as using bulkhea4s3
interior 5urniture or other 5eatures to achie2e the re8uire4 rein5orcement3 but res"onsibl
4esigne4 an4 built metal boats3 )hether o5 steel or aluminum3 definitely do use 5raming*
Des"ite
recent talk
about
A5ramelessA
construction3
res"onsibl
4esigne4 an4
built metal
boats 4o use
5raming* The
a44e4 "late
thickness
re8uire4 to
5orego
5raming
com"letel
)oul4 ren4er
a hea2 hull
in4ee4* Here3
Cust three out
o5 a total o5
,. trans2erse
5rames 5or
this 4esign
are illustrate4*
Without the ai4 o5 metal internal 5raming3 man metal boats are success5ull "late43 an4 the
"lating then is )el4e4 together "rior to the a44ition o5 the 5rames* This construction
techni8ue ren4ers a high 4egree o5 5airness*
Other metho4s use a A5ol4e4 "lateA strateg3 )ith "erha"s one large "late "er si4e3 to make
the "lating much 5aster to erect* To gi2e the 2essel a4e8uate strength in the 5inal "ro4uct3
though3 5rames must be a44e4 be5ore the hull can be consi4ere4 5inishe4*
Man so-calle4 A5ramelessA boats make e6tensi2e use o5 longitu4inals3 )hich3 in A5ol4e4-
"lateA construction3 are o5ten "re-)el4e4 to the "late* Bulkhea4s or other internal trans2erse
structures are use4 to re4uce the s"an o5 these longitu4inals* Strictl s"eaking3 then3 these
boats 4o ha2e 5raming3 an4 )ith goo4 4esign3 the 5raming )ill be a4e8uate to the task*
Classi5ication societies3 such as the American Bureau o5 Shi""ing3 #lo4s3 an4 Det (orske
Keritas are some)hat conser2ati2e in their a""roach3 but )orking through their 5ormulae
4emonstrates the bene5it o5 5raming3 "rimaril to bring the )eight o5 the 2essel )ithin a
reasonable range )hile maintaining the re8uire4 hull rigi4it*
Stu4ies o5 5ailures in aluminum cre) boats an4 o55shore su""l 2essels sho) the nee4 5or
being 2er conser2ati2e in terms o5 the allo)able areas o5 unsu""orte4 "lating3 in terms o5
scantlings 5or 5raming3 an4 in terms o5 the )el4ing bet)een 5rames an4 "lating*
Most o5ten3 the best 5raming stle makes use o5 a series o5 strong trans2erse 5rames
combine4 )ith longitu4inals )hich "ro2i4e the "rimar su""ort 5or the "lating* The longs3
then3 are hel4 b the 5rames*
In m 2ie)3 the 5rames in a metal boat shoul4 al)as be locate4 )here re8uire4 b the
interior bulkhea4s* Bulkhea4s can then be bolte4 4irectl to these )eb 5rames3 an4 all is as
it shoul4 be3 sim"le an4 strong*
With a 5e) tricks o5 the tra4e u" our slee2e3 an absolutel 5air hull is the result*
Some boats are built A'rames 'irstA )hile others are built b a""ling the A!lating 'irstA as
4escribe4 abo2e* 'or 5urther rea4ing about the 2arious a42antages o5 each3 "lease see our
online article? Metal Boat Buil4ing Metho4s.

On Protection And Coatings
Aluminum allos 5or use on boats are generall limite4 to the >000 an4 7000 series* These
t)o allo grou"s are both corrosion resistant in the marine en2ironment 4ue to the
5ormation o5 a tough aluminum o6i4e*
Aluminum allos are subCect to cre2ice corrosion3 since the 4e"en4 on the "resence o5
o6gen to re"air themsel2es* What this means is that )here2er aluminum is in contact )ith
anthing3 e2en another "iece o5 aluminum or @inc3 it must be "ainte4 )ith an a4hesi2e
)ater"roo5 "aint such as e"o63 or it must be "rotecte4 )ith a )ater"roo5 a4hesi2e be44ing3
or both* A "lastic )a5er alone as an isolator is not enough* Salt )ater must be "re2ente4
5rom entering the cre2ice< other)ise corrosion )ill result*
Ano4i@ing3 a "rocess o5 electricall causing the 5ormation o5 a tough o6i4e 5ilm on the
sur5ace o5 aluminum3 slo)s "itting3 but ano4i@ing )ill not "re2ent "itting or cre2ice
corrosion*
Aluminum is 2er acti2e gal2anicall an4 )ill sacri5ice itsel5 to an other metal it contacts
either 4irectl or in4irectl* Aluminum is ano4ic to e2erthing e6ce"t @inc an4 magnesium3
an4 must be electricall isolate4 5rom other metals* In this case3 "aint3 be44ing3 an4 a non-
con4ucti2e "lastic or rubber isolator shoul4 all be use4 together* %nlike tankers3 small
metal boats are not 4esigne4 )ith an a""reciable corrosion allo)ance*
In terms o5 the "aint sstem3 aluminum boats are 4ealt )ith more easil than steel boats*
Aluminum must be "ainte4 )here2er things are mounte4 to the aluminum sur5ace3 an4
belo) the )aterline i5 le5t in the )ater ear-roun4* Other)ise3 marine aluminum allos 4o
not re8uire "ainting at all*
!resent technolog 5or "rotecting metal boats is "lain an4 sim"le? e"o6 "aint* Once the
metal is "rotecte4 )ith a ,/- to ,7-mil 4r-5ilm thickness o5 e"o63 it can then be to"
coate4 )ith )hate2er is a""ro"riate to the situation*
The to" coats can be3 5or e6am"le3 5oam3 enamel3 linear "olurethane3 or bottom "aint*
More 4urable to"-coats better "rotect the in2estment in e"o6* To assure that this
Asecon4ar sstemA sticks to the e"o6 barrier3 use a stan4ar4 e6ten4e4-recoat-time e"o6
"rimer3 )hich makes an e6cellent tie-coat*
'or anti-5ouling "aint3 the e6cellent o55erings 5rom the G-!aint Com"an shoul4 be o5
interest to metal-boat o)ners* Calle4 A(o-'oul3A these "aints release h4rogen "ero6i4e to
"re2ent marine gro)th3 eliminating the inherent "roblems that accom"an co""er-base4
"aints on aluminum hulls*
Whether on steel or on aluminum sur5aces3 "aint "re"aration is critical* Thorough cleaning
an4 san4blasting "ro2i4e the best sur5ace 5or a4hesion o5 "aint or be44ing* Alternatel 5or
aluminum3 cleaning an4 then grin4ing )ith a coarse ,7-grit 4isk )ill "ro2i4e enough tooth
5or the "aint to sta "ut* I5 the sur5ace 5inish must be e6tra 5ine3 as on an aluminum s"ar3
then a thorough san4ing3 cleaning an4 etching )ith a "ro4uct like Alo4ine be5ore "ainting
)ill gi2e goo4 results*
The interior o5 an aluminum boat 4oes not re8uire "ainting* It )oul4 be the ultimate3
though3 to e"o6 "rime the interior i5 a blo)n-in urethane 5oam )ill be use4* A chromate4
2inl-aci4 A)ash "rimerA )oul4 be a 2er acce"table secon4 choice insi4e3 in or4er to
"ro2i4e the best sur5ace 5or a4hesion 5or the 5oam*
&egar4less o5 the bottom "aint use43 @incs must be use4 to control stra-current corrosion3
to )hich )e can become 2ictim )ith a metal boat3 e2en )ithout an electrical sstem+ With
a scratch at the bo)3 an4 another at the stern3 the boat itsel5 becomes the "re5erre4 "ath 5or
an ambient currents in the )ater* In the best o5 all "ossible )orl4s3 there )oul4 be no stra
currents in our harbors3 but that is not realit*
Linc ano4es shoul4 al)as be use4 on an aluminum boat3 an4 generall in the same
8uantities as )ith a steel boat3 in or4er to "re2ent stra-current corrosion* The 8uantit an4
"lacement o5 @incs are 4isco2ere4 b e6"eriment o2er time3 an4 )ill 4i55er 5rom one marina
to the ne6t*
As an e6am"le3 on a =0-5oot metal hull3 the best scheme is to start )ith t)o @incs 5or)ar43
t)o a5t3 an4 one on each si4e o5 the ru44er* With a larger boat3 sa o2er => 5eet3 an
a44itional "air o5 @incs ami4shi"s )oul4 be a""ro"riate* Sur5ace area3 not @inc 2olume3 is
the im"ortant 5actor*
A5ter the 5irst 5e) months3 ins"ect the @incs* I5 the a""ear acti2e but "lent o5 material
remains3 the @incs are 4oing their Cob* I5 the are seriousl )aste43 the area as )ell as the
)eight o5 @inc shoul4 be increase4*
O5 course3 )el4ing @incs on is best3 but 5or an aluminum boat3 the @incs )ill instea4 usuall
be bolte4 to stu4s )el4e4 onto the hull "late3 or bolte4 using stainless bolts into a hea2
bolting "late )el4e4 to the hull* Goo4 electrical connection bet)een the @inc an4 the hull is
im"erati2e*

he Bottom !ine
Can aluminum com"ete )ith 5iberglass as a "ro4uction hull materialF
Jimm CornellDs Ocean Cruising Sur2e3 a 2aluable in4icator o5 tren4s among )orl4-
2oaging cruisers3 sho)s that metal boats are on the increase* A metal hull )as the number-
one )ish o5 those )ith other hull materials* AM ne6t boat )ill be metal***A )as hear4 o2er
an4 o2er3 "articularl b those )ho )ere alrea4 cruising aboar4 a metal boat*
It is sai4 among 4e4icate4 blue )ater cruisers in the South !aci5ic3 A>0E o5 the boats are
metal< the rest o5 them are 5rom the %nite4 States****A Although it ma seem so at times3
this statement is 5ortunatel not ,00E true++
In terms o5 cost3 )e usuall obser2e that 4is"lacement is more im"ortant than length*
Aluminum is the i4eal material 5or buil4ing a light)eight boat*
The secon4 cost 4eterminant is com"le6it* This reaches into all as"ects o5 the 4esign3
inclu4ing hull sha"e* The sim"ler the 4esign3 the lo)er the cost* 'or e6am"le3 a )ell-
4esigne4 single-chine hull )ill "er5orm e6tremel )ell3 an4 the sa2ings )ill allo) a
slightl longer boat* Dollar 5or 4ollar3 this translates into a MrealM "er5ormance a42antage*
With correctl a""lie4 "rotecti2e coatings )here nee4e43 a4e8uate @incs3 a "ro"er electrical
sstem3 an4 goo4 care o2er time3 an aluminum boat )ill last in4e5initel*

Further Considerations...?
We belie2e in metal as the ultimate boat structure3 an4 as a result )e ha2e create4 8uite a
number o5 metal boat 4esigns* To re2ie) them3 "lease see our Sail Boats Galler an4 our
!o)er Boats Galler* We ha2e also create4 8uite a number o5 !rotot"e Designs3 most o5
)hich are also inten4e4 5or metal structure* Sail or "o)er - mono or multi-hull - i5 the
structure is )ell-4esigne4 an4 )ell built3 the resulting boat )ill be e6cellent*
We are o5ten aske4 about one metal 2s* another - most commonl steel 2s* aluminum*
Des"ite the e6cellent case )e ha2e ma4e 5or aluminum abo2e3 )e 4o not ha2e a 4istinct
"re5erence* There are so man 2aring 5actors that )ill contribute to making that 4ecision
5or each boat3 an4 5or each o)ner* Some boats are 4esigne4 5or one material onl3 other
boats can make use o5 either*
In general3 an o5 our 4esigns that ha2e been 4e2elo"e4 5or steel can 2er 8uickl be re-
s"eci5ie4 5or construction in aluminum* The 4esign con2ersion 5rom steel to aluminum is
4one 5or a minimal e6tra cost* Where (C cutting 5iles e6ist 5or a steel boat3 the )ill nee4
to be re-4one in or4er to )ork 5or aluminum structure3 an4 there )ill be a cost incurre4 5or
that con2ersion*
Designs originall 4e2elo"e4 5or aluminum structure are not as rea4il con2erte43 since
the )ill ha2e been 4esigne4 s"eci5icall to sa2e )eight* To con2ert an aluminum 4esign
to steel )ill or4inaril re8uire a re-)ork o5 the hull sha"e in or4er to su""ort the e6tra
)eight o5 steel*
I5 a con2ersion o5 one o5 our 4esigns 5rom steel to aluminum or 2ice 2ersa is o5 interest3
"lease in8uire*
'or more in5ormation on the 8uestion o5 hull materials3 "lease see our )eb articles on the
5ollo)ing?
Metal Boats 5or Blue Water | Aluminum 5or Boats | Aluminum 2s* Steel | Steel Boats |
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Co"right ,--. - /00- Michael 1asten
"irect #uote 5rom an aluminum boat o)ner***
As an o)ner since > ears o5 an aluminum boat I coul4 not agree more )ith our
"re5erence 5or this material* She is a great sailboat an4 re8uires 2er little in the )a o5
maintenance* I 4o a lot more ree5 snorkeling than the "aint3 "olish3 2arnish an4 )a6 gus+
--!eter 1minek
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Frames First... or Plates First...?
A "iscussion of $etal Boat Building $ethods
There are a number o5 a""roaches one can take )hen 5abricating a ne) metal boat* Among
them are metho4s that erect the 5raming 5irst an4 a""l the "lating to that structure
a5ter)ar43 an4 others that 5a2or "re-"lanning the "late sha"es in or4er to create the hull
sha"e be5ore the 5rames are intro4uce4 insi4e* The 5ollo)ing is a 4iscussion o5 the 2arious
a""roaches taken3 their rationale an4 the "ros an4 cons o5 each*
With e6treme luck3 the 5ollo)ing )ill be taken as inten4e4 - "urel 5or in5ormationDs sake*
I ho"e also it )ill she4 light on )hat has in the amateur metal boat buil4ing )orl4 become
at times a heate4 4ebate*
You can re2ie) our a""roach to the 2arious metal boat buil4ing metho4s in our article on
Aluminum 5or Boats )here the are 4iscusse4 in 4etail3 inclu4ing the 2arious "ros an4 cons
o5 each a""roach to)ar4 5abricating* In that article an4 among the links "ro2i4e4 there
ouDll also 5in4 our thoughts on boat sha"e itsel5? single 2s* multi-chine 2s* ra4ius chine 2s*
roun4e4 hull3 etc*
&ather than to 4iscuss the merits o5 4i55erent hull sha"es here3 )e )ill limit oursel2es to the
8uestion o5 Build $ethods*
In this article I )ill 4i2i4e the 2arious metal boat buil4ing a""roaches into t)o broa4
categories o5 B%I#D MGTHODS3 an4 then I )ill a44ress a 5e) basic notions regar4ing
ST&%CT%&G*
http://www.kastenmarine.com/+rames,+irst.htm
The main thing I ho"e to accom"lish here is to attem"t to define an4 to there5ore hel" the
rea4er to un4erstan4 the 2arious 4i55erent terms being use4 )hen 4iscussing 4i55erent
boatbuil4ing metho4s*
Here are se2eral thoughts that I ho"e ma hel" clari5 the "icture***

Structure
'irst3 in terms o5 ST&%CT%&G3 )e ha2e in recent ears encountere4 se2eral "ro"onents o5
so-calle4 AframelessA construction* %n5ortunatel3 )hen the )or4 A5ramelessA is use4 it is
commonl mis-construe4 to im"l that a 2essel can 4o entirel )ithout internal structure*
&egar4less o5 the 2arious a""roaches taken to)ar4 5abricating an4 "late 4e2elo"ment 5or
boats3 there )ill al)as be a re8uirement 5or hull "late rein5orcements3 )hether the occur
in the 5orm o5 5loors3 longitu4inal stringers3 bulkhea4s3 )eb 5rames3 mast ste"s3 engine
gir4ers3 tank 5aces3 4eck beams3 or )hate2er* These are all 2arious t"es o5 internal
rein5orcements3 an o5 )hich )ill legitimatel 8uali5 5or the term A5raming*A
The 2er notion o5 A5ramelessA metal boat construction is b 4e5inition there5ore a 5la)e4
an4 incorrect conce"t inso5ar as it re5ers to the "ossibilit o5 a com"lete4 2essel being able
to e6ist entirel )ithout 5rames or other internal metal structure*
While it is certainl "ossible to increase "late thickness in or4er to increase 5rame s"acing
an4 to there5ore re4uce the number o5 5rames3 it is not at all 4esirable to eliminate 5rames
altogether* G2en )ith aluminum3 the thickness o5 "late re8uire4 to com"letel eliminate
5rames )oul4 en4 u" )eighing 5ar too much 9an4 )oul4 cost too much: to be "ractical*
Our a""roach to the so-calle4 AframelessA metal boat construction metho4s are a44resse4
thoroughl )ithin our article on Aluminum 5or Boats3 in our article on Metal Boats 5or
Blue Water an4 belo) un4er the hea4ing3 The Ouestion o5 !e4igree***

Build Methods
In terms o5 B%I#D MGTHODS3 )e obser2e the 5ollo)ing broa4 categories?
-. .Framing First. with the plating /eing patterne0 an0 applie0 to the alrea0y
erecte0 +rame1 an0
2. .Plating First. with the +rames patterne0 to the alrea0y erecte0 an0 wel0e0
plating 3 o+ten making use o+ temporary moul0s to help gui0e the plate an0
maintain the inten0e0 hull shape.
This latter metho4 is o5ten incorrectl re5erre4 to as being A5ramelessA because the "lating
occurs "rior to the 5rames being intro4uce4* This is most un5ortunate terminolog3 is
inaccurate an4 there5ore mislea4ing3 an4 is all too o5ten cause 5or misun4erstan4ing an4
unnecessar argument*

The "Frame First" Method
With the Frame%First metho43 the hull sha"e is controlle4 b 5irst ha2ing a rigi4
AarmatureA o2er )hich the "lating is a""lie43 in other )or4s? the 5rames* The "rimar
a42antage o5 this metho4 is that it allo)s e6act control o2er the sha"e* As a result it is b
5ar the most common a""roach to metal boat buil4ing3 )hether being use4 5or shi"s 9nearl
,00E use4: or 5or achts 9"ossibl -0E use4 i5 Guro"e is inclu4e4:*
WeDll limit our 4iscussion to small achts here 9boats un4er aroun4 70 5eet:3 so )e nee4 not
in2ol2e metho4s use4 5or larger 2essels such as modular construction*
In or4er to achie2e a 5air e6terior hull sur5ace3 the A5rame-5irstA metho4 re8uires that the
&uilder be skille4 in the lo5ting3 the set-u" o5 the 5rames3 the "atterning o5 the "late3 an4 the
5inal )el4-u" o5 the hull* It is o5 course e6acting )ork to achie2e this le2el o5 "recision an4
5airness in the com"lete4 hull3 but the attention to 4etail is )ell )orth it in the en4**
The 8uestion then becomes3 "Ho' shall 'e sa(e the &uilder time...?"
With the A5rame-5irstA metho43 8uite a lot o5 the buil4erDs 5abricating time can be sa2e4 b
ha2ing all the 5rames an4 "lating "re-"lanne4 b CAD an4 "re-cut b )C Cutting 2ia
"lasma or )ater Cet* What is (C***F It literall means A(umericall Controlle4*A
The high le2el o5 "recision o55ere4 b (C Cutting takes the tra4itional A5rame-5irstA metho4
to the ne6t le2el*** When using "re-cut metal "arts3 there is no lo5ting nee4e43 an4 there is
no cutting re8uire4 5or the 5rames or "lates or other ke structures* (C Cutting there5ore
"ro2i4es substantial e55iciencies to the buil4er3 thus consi4erable time sa2ings3 in a44ition
to o55ering a 4egree o5 accurac that is sim"l unachie2able b manual lo5ting an4 cutting*
While (C Cutting can e55ect substantial labor sa2ings in the han4s o5 a "ro5essional
buil4er3 it has the "otential to sa2e e(en more time in the han4s o5 an amateur buil4er*
WhF Mainl this is 4ue to the elimination o5 8uite number o5 AWhat 4o I 4o no)FA
8uestions3 an4 the relati2el huge amount o5 time e6"en4e4 on them - ine2itable 5or a 5irst
time buil4er )hen ha2ing to lo5t3 "lan3 s"ile3 an4 cut e2er "art o5 the structure*
(ee4less to sa3 the (C a""roach re8uires a high 4egree o5 skill an4 actual buil4ing
e6"erience on the "art o5 the 2esselDs designer in or4er to be able to "attern all the 5rames3
"lates3 an4 other "arts correctl* It also re8uires a high 4egree o5 accurac on the "art o5
the &uilder )ho must then "lace e2erthing as inten4e43 i*e* e6actl )here it belongs*
Or4inaril )hen using (C Cutting3 asi4e 5rom Cust the 5rame sha"es being "re-4e5ine43 the
5rames )ill also ha2e mouse holes 5or )el4-throughs3 an4 )ill ha2e notches "re-cut to
recei2e the longitu4inal stringers* A44itionall3 there )ill be all the other "arts such as the
engine gir4ers3 tank 5aces an4 li4s3 stem an4 horn "iece sha"es3 mast ste"s3 4eck beams3
bulkhea4s3 an4 o5 course all the e6terior "lating - all o5 it "re-cut to an accurate 5it-u"*
The result o5 these e55orts is that since all "arts are machine-cut to an e6acting sha"e3 an4
the hull can be erecte4 )ith "recision3 the buil4er - amateur or other)ise - can a2oi4 the
4istortion "roblems associate4 )ith "oor 5it-u" o5 "lates*
'or 5urther in5ormation about the (C Cutting "rocess an4 ho) (C Cut 'iles are 4e2elo"e43
)e ha2e "oste4 a number o5 (C cutting articles online*

The "Plate First" Method
With the APlating%FirstA metho43 the "late outlines are "recisel 4e5ine4* The are either
4e2elo"e4 manuall3 or 5rom a ;D "hsical scale mo4el3 or the are 4e5ine4 using a ;D
CAD mo4el* Then the "lates are cut to their "erimeter outline3 an4 arrange4 so the can be
"ulle4 into "lace one b one an4 tacke4 together3 an4 5inall the "lates are )el4e4 u"* This
much can sometimes be 4one )ithout using internal or e6ternal moul4s as a gui4e3 but
more commonl moul4s o5 some sort )ill be use4* The moul4s can be 5rame segments or
the can be other t"es o5 tem"orar gui4es to the sha"e*
A5ter the hull plate seams are )el4e4 u"3 the frames are "atterne4 to the interior o5 the hull
"lating3 then the 5rames are installe4 an4 )el4e4 in "lace*
The "rimar a42antage o5 "lacing the 5rames after'ard is to allo) the "lating to be )el4e4
u" 5irst )ithout there being an "otential 4istortion intro4uce4 b the "resence o5 a
relati2el un-iel4ing 5rame insi4e* This can "ro4uce an e6tremel 5air hull3 an4 can 4o so
e2en )ithout there being much skill in2ol2e4 on the "art o5 the buil4er3 thus although it has
enormous a""eal to amateur or back-ar4 buil4ers3 it also has substantial a""eal to man
"ro5essional boat buil4ers* It is 5or e6am"le the most common metho4 in use throughout
the (etherlan4s3 )here there is a 2er highl 4e2elo"e4 metal boat buil4ing in4ustr*
The main 4isa42antages o5 the A"late 5irstA a""roach are?
*hat unless the plating is patterne0 4ery accurately there can /e unpre0icte0
4ariations in the shape o+ the hull1 there /eing no internal +rame to control the
o4erall shape1 nor to pro4i0e an in0ication that the hull shape may /e turning out
0i++erently than inten0e05 an0
*hat the actual shape o+ the hull must con+orm to what is a rea0ily 0e4elopa/le
plate shape1 limiting the 0esign somewhat.
This Ahull sha"eA restriction is the onl signi5icant 4ra)back to the A"late-5irstA metho4* It
Cust means that the 4esigner must use 5ull A4e2elo"ableA hull 5orms* Though this limits
)hat is "ossible aestheticall an4 in terms o5 being able to o"timi@e the un4er)ater hull
5orm3 it is 5ortunatel not a cri""ling limitation***+
When )e are 4iscussing an o5 the 2arious Aplate%firstA metho4s3 it shoul4 be recogni@e4
that this a""roach is reall onl a""licable to the hull bottom an4 si4e "lating3 "ossibl
inclu4ing the transom* This metho4 ho)e2er is generall not a""licable to a""en4ages
such as the keel or ru44er3 nor or4inaril to the 4eck an4 house structures* There5ore3 reall
onl about ;>E to >0E o5 the 2esselDs total "lating sur5ace is e2en un4er consi4eration
)hen re5erring to an o5 the plate first metho4s*
Just as )ith the A5rame 5irstA metho43 in or4er to a44ress the issue o5 accurac3 the A"lating
5irstA metho4 can take e6cellent a42antage o5 CAD 5or "atterning an4 (C cutting* This
a""roach )ill iel4 an e6tremel "recise "late 4e5inition an4 conse8uent cutout3 an4
there5ore )ill "ro2i4e a much more accurate as-)el4e4 hull sha"e*
B using (C cutting3 the 5rames too can be "re-"lanne4 an4 "re-cut3 making allo)ances at
their Coins 5or the ine2itable small 2ariations intro4uce4 b the )el4 shrinkage 4uring the
)el4-u" o5 the "lating "rior to the 5rames being "ut in "lace*
It shoul4 be mentione4 that e2en )hen using the A"late-5irstA a""roach3 it ma be
a42antageous to attach a number o5 internal 5rame members to the "lating "rior to it being
o55ere4 u" to the boat3 in "articular this )ill o5ten a""l to the longitu4inal stringers*
This kin4 o5 Aplate%firstA a""roach is rather common among "ro5essional buil4ers in the
(etherlan4s* O5ten3 5rames are "lace4 as there are o""ortunities to 4o so in or4er to retain
the o2erall sha"e* 'or e6am"le3 once the bottom "lating an4 longitu4inal stringers are in
"lace an4 )el4e4 to the keel si4es3 internal bottom 5rames can be intro4uce4 )hile the
structure is easil accesse43 then the to"si4e "lating attache4 an4 )el4e4 u" "rior to
intro4uction o5 the si4e 5rames* This results in an e6tremel 5air hull3 as )ell as a highl
accurate sha"e*
In m 2ie)3 this hy&rid strategy has the most to o55er3 es"eciall )hen use4 )ith (C
cutting* In or4er 5or the designer to "lan the sha"e an4 the (C cutting so that construction
can "rocee4 smoothl3 it must be 4etermine4 in a42ance Cust )hat se8uence the &uilder
)ill use to assemble the "lates an4 5rames*

Variations on a Theme...
Within the A"late-5irstA a""roach3 there are t)o main 4i2isions?
-. *he .Pre-Cut-Plate. metho0 as 0escri/e0 a/o4e1 an0
2. *he .Folded-Plate. or so3calle0 Origami metho0.
With the APre%Cut%PlateA a""roach3 the "lating is all "lanne4 5or 4e2elo"abilit 9cur2ature
in one 4irection onl3 i*e* not sa44le sha"e4 or 4ome sha"e4:* Here3 the "lating is all "re-
cut3 "ulle4 into "lace - or4inaril o2er a moul4 or tem"orar su""orts - then stitche4
together along the seams* This is essentiall the A"late-5irstA metho4 4escribe4 abo2e*
Taking this "re-cut-"late a""roach one ste" 5arther3 )e ha2e the AFolded PlateA or
Origami metho43 )hereb as man o5 the hull "late )el4 seams as "ossible are eliminate4
2ia an ingenious laout o5 the seams an4 a sha"e that allo)s there to be a number o5 A"re-
Coine4A areas*
The a42antage o5 the A'ol4e4 !lateA metho4 is that )ith an accuratel "re-"lanne4 outline
thatDs cut out o5 "late3 the entire hull "lating can 5irst be lai4 out 5lat - "ort an4 starboar4 -
)el4e4 )here necessar to create the si@es an4 sha"es re8uire43 then itDs all "ulle4 together
an4 stitche4 into "lace* %sing this metho43 once the "late sha"es ha2e been 4etermine43 the
hull "lating can be erecte4 in a 2er short time - o5ten in a matter o5 4as*
O5 course this looks im"ressi2e***+ It actuall is im"ressi2e+ (aturall this conce"t has
ca"ture4 the imagination o5 the amateur metal boat buil4ing communit3 thus a "ossibl
signi5icant contingent among "otential o)ner-buil4ers*
With the Folded Plate * Origami metho4 ho)e2er3 one must reali@e that the 4esigner is
un5ortunatel e6tremel limite4 in terms o5 the "ossible hull sha"es that )ill actuall 4o
this trick* Tr it )ith "a"er cutouts an4 ou )ill be imme4iatel con2ince4* You can
achie2e a 5e) minor 2ariations an4 still get sha"es that )ill 5ol4 together3 but regional
subtleties o5 hull 5orm are Cust not "ossible* I5 a 4i55erent t"e o5 hull 5orm is 4esire43 then
8uite a lot o5 trial an4 error time must be s"ent - usuall b making actual trial cutouts an4
seeing i5 the )ill 5it together in an attem"t to 4isco2er a totall 5lat "late laout that )ill
"ro2i4e the inten4e4 sha"e )hen 5ol4e4 together*
This is not onl a se2ere limitation on the designer - it also restricts the &uilder )ho ma
as a result ha2e onl one basic mo4el to o55er* In other )or4s3 2ariations to the hull sha"e
are 4i55icult an4 time consuming to create3 so the 2essels are limite4 to being either larger
or smaller3 5atter or more slen4er3 taller or shorter3 ha2ing more or less sheer3 et essentiall
the same in their general sha"e an4 a""earance*
'urther3 it must be ke"t in min4 that Cust as )ith the A"re-cut-"lateA metho43 the A'ol4e4-
!lateA or Origami metho4 is generall onl a""licable to the hull "lating itsel53 an4 not to
the keel3 ru44er3 4eck3 or su"erstructure*
We obser2e then the 5ollo)ing 4isa42antages o5 the AOrigamiA metho4?
-. #nly a limite0 portion o+ the total plate sur+ace will /e a00resse0 /y the #rigami
metho05
2. *he 4ariety o+ hull shapes that are possi/le /oth aesthetically an0 +unctionally are
6uite limite05
7. *here will /e 6uite a lot o+ +ussing aroun0 with trial shapes prior to achie4ing the
0esire0 result.
As a result o5 these 5actors3 I ha2e not so-5ar been tem"te4 to "ursue the Origami a""roach
in m 4esign )ork*
G6ce"t 5or the initial A)o)A 5actor3 )hich hol4s a certain )ell 4eser2e4 a""eal among
amateur boat buil4ers3 I 4onDt see much a42antage to it3 es"eciall in a "ro5essional boat
buil4ing conte6t* In "articular3 this is so 4ue to the e6treme restriction on the 2ariet o5
"ossible hull sha"es that can be o55ere4* The hull sha"es become e6tremel alike3 there5ore
or4inar an4 uninteresting*
Ask an o5 the "ro"onents o5 the Origami metho4 ho) man trul A4i55erentA hull sha"es
the ha2e been able to 4esign or buil4 using that a""roach 9hulls )hich are not sim"l
stretche4 or s8uishe4 2ersions o5 the same thing:3 an4 I belie2e ouDll imme4iatel see )hat
I mean*
One can Cust as easil make use o5 the Apre%cut%plateA a""roach3 an4 ha2e consi4erabl
more 5ree4om )ith subtleties o5 hull 5orm*

Strategy...?
I5 one is able to begin )ith a blank sheet3 in other )or4s i5 one is able to create a ne)
custom acht 4esign3 it becomes "ossible to choose bet)een a 5rame-5irst 2s* a "late-5irst
buil4ing metho4* In this case3 the 5irst task in the 4esign ccle belongs to the o)ner3 an4
that is to 5in4 a 4esigner )ho can bring about the o)nerDs 2ision an4 "ur"ose 5or the 2essel
the ha2e in min4*
The 4esignerDs role is to act as the o)nerDs a42ocate throughout the )hole "rocess3
attem"ting to mel4 their re8uirements P re8uests )ith )hat is "ractical P achie2able P sa5e P
etc*3 at the same time as attem"ting to achie2e the aesthetic3 the laout3 an4 the "er5ormance
being sought* Then once the 2essel has been 4esigne43 to 5ollo) through 4uring the
construction o5 the 2essel3 5irst to connect the o)ner )ith a buil4er )ho is suite4 to the
task3 an4 then to 5ollo) through 4uring construction to assure that )hat has been 4esigne4
gets built as "lanne4*
Occasionall this or4er o5 e2ents gets turne4 aroun43 an4 the o)ner 5irst 5in4s a suitable
buil4er3 then together the 5orage 5or a 4esign that the o)ner likes an4 that the buil4er
)ants to buil4* While this can o5ten result in great success3 it can also result in great
com"romise* Ho)e2er i5 the com"romise is not too great3 an4 the cost is attracti2e3 then a
4eal ma be struck that is satis5ing to all in2ol2e4*
More o5ten than not though the buil4er or the o)ner )ill )ant to intro4uce changes to the
4esign* Subtle 2ariations to the interior3 usuall intro4uce4 b the o)ner3 are to be
e6"ecte4 an4 are usuall not o5 an conse8uence*
MaCor changes to the laout that in2ol2e changes to the structure3 or that in2ol2e relocating
tanks3 bulkhea4s3 engines3 maCor machiner3 masts3 etc* are 2er o5ten sought* Ho)e2er3
an o5 these kin4s o5 changes must necessaril in2ol2e the 4esigner*
What is not o5ten reali@e4 is that collecti2el3 these changes can 8uickl eliminate an
"ossible a42antage to ha2ing selecte4 a stock 4esign* At this "oint3 it can become
a42antageous to begin 5rom a blank sheet - e2en i5 it is largel base4 on a "rior 4esign*
Thus3 our nearl ,00E 5ocus on ne) custom acht 4esign*
I5 a stock 4esign is entirel suitable as is3 or i5 minor changes are all thatDs nee4e43 then
certainl the 4esigner )ill be able to Acustomi@eA that 4esign to suit - it is all "art o5 a
4esignerDs usual routine*

The Question of Pedigree...
All the buil4ing metho4s mentione4 abo2e can be ma4e to satis5 the structural
re8uirements o5 the ABS or other rules - )ith the e6ce"tion o5 the so-calle4 A5ramelessA
buil4ing metho43 )hich cannot* In consi4ering an e6isting 4esign3 one shoul4 in8uire as
to )hether the structure has been 4esigne4 accor4ing to the stan4ar4s o5 one or more o5 the
acht classi5ication societies*
'or motor 2essels3 )e calculate structure "er the re8uirements o5 the ABS &ule 5or Motor
!leasure Yachts3 or 5or sail boats3 the ABS &ule 5or Ocean &acing Yachts3 or both3 taking
the most conser2ati2e result 5rom each3 then a44ing our o)n 5actor o5 sa5et* We also
consult a""licable "ortions o5 the German #lo4Ds rule an4 other classi5ication societ rules
such as #lo4Ds &egister )here2er the ma be a""ro"riate3 such as 5or s"ars an4 rigging or
5or )oo4en structures3 etc*
Asi4e 5rom the structure3 )hen in8uiring about an stock 4esign or ne) custom 4esign it
)ill be "ru4ent to in8uire about the sta&ility com"liance o5 the 2essel being consi4ere4*
'or e6am"le3 )e im"ose the G% &ecreational Cra5t Directi2e stabilit re8uirements on our
4esigns - both sail an4 "o)er* G2en though there are legall no stabilit stan4ar4s im"ose4
on "leasure cra5t built an4 registere4 in the %S3 )e 5eel this is 8uite im"ortant3 there5ore the
G%-&CD is our base-line stan4ar4*
You can rea4 about our rationale 5or use o5 these stan4ar4s3 )hat the mean3 an4 ho) the
a""l b re2ie)ing our 2arious articles relate4 to ABoat DesignA on the Articles )eb "age*
In terms o5 sa5et e8ui"ment3 )hile )e 2er much a42ocate the use o5 the ABYC
gui4elines 5or sa5et an4 sstems3 there are a 5e) s"eci5ic areas )here )e 4isagree )ith the
ABYC recommen4ations* Mainl this is limite4 to those cha"ters )here the ABYC
gui4elines are at "resent ina4e8uatel 4e2elo"e4 an4 are ra"i4l changing - in "articular
)ith regar4 to bon4ing an4 electrical isolation on metal 2essels* We a44ress these matters
thoroughl in our Kessel S"eci5ication )hich accom"anies each 4esign3 o5ten amounting to
)ell o2er >0 "ages*

Conclusions
A number o5 our 4esigns are 5ull 4e2elo"able3 an4 are thus 4irectl a4a"table to the A"re-
cut "late-5irstA a""roach3 in "articular i5 (C cutting )ere to be em"loe4* G6am"les that
come to min4 are the ;7D ketch Grace an4 her larger sisters? the =/D schooner Highlan4 #ass
an4 the =/D ketch Le"hr3 )hich ha2e 5ull 4e2elo"able hulls*
Man o5 our other 4esigns3 )hile largel 4e2elo"able3 ha2e intentionall 2iolate4
4e2elo"abilit locall in or4er to achie2e the right aesthetic sha"e or the right 4istribution
o5 4is"lacement or the right )aterlines or buttock lines3 etc* G6am"les inclu4e the ==D
schooner &e4"ath or those 4esigns 5or )hich a rounded hull 5orm )as "re5erre4 such as
the ;7D cutter 'antom3 the =0D schooner Benrogin3 or the >0D schooner #ucille*
Although )e ha2e no "articular interest in "ursuing the AorigamiA a""roach as such3 )e 4o
belie2e there to be consi4erable merit to the A"re-cut-"late-5irstA a""roach* More
"articularl )e ha2e obser2e4 big a42antages to the hbri4 A"lates-5irst-then-5rame-as-ou-
goA a""roach mentione4 abo2e* G2en though hull sha"es are thus limite4 to onl )hat is
4e2elo"able3 there are innumerable goo4 sha"es that one can achie2e )hich are
aestheticall "leasing an4 that ha2e a )ater-5rien4l sha"e*
To be a success3 the "re-cut "late sha"es must be "recisel "lanne4 an4 cut3 but this is not
at all 4i55icult )hen combine4 )ith CAD 4ri2en (C cutting* We ha2e 4e2elo"e4 (C
cutting 5iles 5or a number o5 our 4esigns3 an4 )eDre continuall in2ol2e4 in the 4e2elo"ment
o5 ne) 4esigns - an4 o5 (C 5iles to ease their construction*

Further Considerations...?
We belie2e in metal as the ultimate boat structure3 an4 as a result )e ha2e create4 8uite a
number o5 metal boat 4esigns* To re2ie) them3 "lease see our Sail Boats Galler an4 our
!o)er Boats Galler* We ha2e also create4 8uite a number o5 !rotot"e Designs3 most o5
)hich are also inten4e4 5or metal structure* Sail or "o)er - mono or multi-hull - i5 the
structure is )ell-4esigne4 an4 )ell built3 the resulting boat )ill be e6cellent*
We are o5ten aske4 about one metal 2s* another - most commonl steel 2s* aluminum* We
4o not ha2e a 4istinct "re5erence* There are so man 2aring 5actors that )ill contribute to
making that 4ecision 5or each boat3 an4 5or each o)ner* Some boats are 4esigne4 5or one
material onl3 other boats can make use o5 either*
In general3 an o5 our 4esigns that ha2e been 4e2elo"e4 5or steel can 2er 8uickl be re-
s"eci5ie4 5or construction in aluminum* The 4esign con2ersion 5rom steel to aluminum is
4one at no e6tra cost* Where (C cutting 5iles e6ist 5or a steel boat3 the )ill nee4 to be re-
4one in or4er to )ork 5or aluminum structure3 an4 there )ill be a cost incurre4 5or that
con2ersion* I5 thatDs o5 interest3 "lease in8uire*
Designs that )ere originall 4e2elo"e4 5or aluminum structure are not as rea4il con2erte43
since the )ill ha2e been 4esigne4 s"eci5icall to sa2e )eight* To con2ert one o5 them to
steel structure )ill or4inaril re8uire a re-)ork o5 the hull sha"e in or4er to su""ort the
e6tra )eight o5 steel* 'or some boats3 that is not much trouble* 'or other boats3 in
"articular small ones3 steel ma not e2en be an o"tion* I5 a con2ersion to steel is o5 interest
5or one o5 our aluminum 4esigns3 "lease in8uire* 5or more in5ormation*
You )ill 5in4 more in5ormation about costs an4 other consi4erations bet)een these metals
among the essas linke4 5rom our Articles )eb "age3 an4 es"eciall in the t)o articles
liste4 belo)*
'or more in5ormation about an o5 the abo2e3 "lease 5eel 5ree to contact me*
+elated Articles
Metal Boats 5or Blue Water | Strength o5 Aluminum 2s Steel
!lease see the !lans #ist "age to re2ie) our a2ailable Boat !lans*
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Boat Materials
Aluminum. We use only the finest materials available. The 5000 series marine grade
aluminum alloy is specifically made for full-time saltwater applications. A!"A#
Aluminum !ompany of America# put a plate of this aluminum in $arragansett Bay# %& for
thirty years and too' it out because nothing was happening. We have chosen the 50()
alloy for the whole hull. This aluminum alloy is the absolute best available and thic' to
boot. With either *+,) or ,+- construction# these boats are .-* times as thic' as
most aluminum boats you may be familiar with. &f youve ever seen a /.0. !oast
1uard -2 footer than youve seen 5000 series aluminum alloy at wor' afloat.
1unwale. This . *+- oval in cross-section e3trusion gives the edge of your boat
incredible durability. Weve had demo rides where a prospective customer
inadvertently slammed the boat into cement pilings with 4ust a slight rub to show for it.
The only reason to own fenders is to protect the other guys boat.
!hine. Along the length of the chine is an e3trusion that both the side and the bottom
plates fit into. This high impact area is then double welded the length of the boat. This
level of 5uality is unheard of even in custom aluminum boats.
$on-0'id. This material is applied to the self bailing dec' and consists of a polyurethane
base and topcoat surrounding an aggressive non-s'id abrasive. $ot for the faint of
heart# nor the bare of foot# this material is similar to the new bedliner material you may
be familiar with as an aftermar'et application in pic'-up truc's. &t gives you tough#
durable# surefooted-ness in all weather conditions.
6oam. We in4ect closed cell foam beneath the self-bailing dec' into all voids below
dec's 7e3cept around the fuel tan'8. This high-end system assures you of both
unsin'ability and upright flotation should you ever swamp the boat.
&n short# no e3pense is spared in ma'ing for you the finest boat available anywhere.
These materials# used for the first time in a production model boat# truly represent the
first in a whole new category of boats.
Blac' ab Marine 9artners# !
.02--00-2-0-
Aluminium Alloys Used in the Marine Industry
"luminium alloys commonly use0 in the marine in0ustry inclu0e:
Aluminium-magnesium allos - >000 series3 use4 "rimaril 5or rolle4 materials
9sheetP"late:* Most common are >0I; Q >;I;*
Aluminium-magnesium-silicon allos - 7000 series3 use4 "rimaril 5or e6tru4e4
sections* Most common are 70I/3 707,3 700>A Q 7070*
Source? Ca"ral Aluminium
'or more in5ormation on this source "lease 2isit Ca"ral Aluminium*
Aluminum Distributing Inc
>0I7-H,,,3 >0I7-H,,73 >0I;-H,,7 aluminum 5or marine useP sheet
)))*a4imetal*comP
Marine rade
Alloy Aluminum
5083
5086
Structural
Marine rade
Alloy Aluminum
6061
Sheet and Plate ,-./0%H110 or -./2%H110
or "ual3
Check up to five results to perform an action.
larger image Se2eral si@es 4ual certi5ie4
he follo'ing specifications co(er Aluminum -./2
OO A/>0P7
Aluminum -./2
Chemistry "ata4
Aluminum? Balance
Chromium? 0*0>R0*/>
Co""er? 0*, ma6*
Iron? 0*= ma6*
Magnesium? =R=*-
Manganese? 0*=R,
&emain4er Gach? 0*0> ma6*
&emain4er Total? 0*,> ma6*
Silicon? 0*= ma6*
Titanium? 0*,> ma6*
Linc? 0*/> ma6*
Aluminum -./0
Chemistry "ata4
Aluminum? Balance
Chromium? 0*0>R0*/>
Co""er? 0*, ma6*
Iron? 0*= ma6*
Magnesium? =R=*-
Manganese? 0*=R,
&emain4er Gach? 0*0> ma6*
&emain4er Total? 0*,> ma6*
Silicon? 0*= ma6*
Titanium? 0*,> ma6*
Linc? 0*/> ma6*
Aluminum 0.01
Chemistry Data :
"luminum : ?alance
Chromium : =.=@ 3 =.7A
Copper : =.-A 3 =.@
Iron : = 3 =.B
Magnesium : =.< 3 -.2
Manganese : =.-A maC
#ther : =.-A maC
&emain0er Dach : =.=A maC
Silicon : =.@ 3 =.<
*itanium : =.-A maC
Einc : =.2A maC
$echanical "ata 4
Aluminum -./2
'orm ? Sheet
Con4ition ? H,,7
Tem"erature ? 7I
Tensile Strength ? =/
Yiel4 Strength ? ;0
Glongation ? ,/
Principal "esign Features
This is a non-heat treatable allo 5or strengthening* It has 2er goo4 corrosion resistance3 is
easil )el4e4 an4 4oes ha2e goo4 strength*
Applications
Commonl use4 in the manu5acture o5 un5ire43 )el4e4 "ressure 2essels3 marine3 auto
aircra5t crogenics3 4rilling rigs3 TK to)ers3 trans"ortation e8ui"ment3 an4 in missile
com"onents*
Aluminum $ill Product Specifications
A(aila&le Forms4
Sheet an4 !late ASTM-B-/I 3 'GDG&A#-OO-A-/>0P.
Aluminum -./0
'orm ? Sheet
Con4ition ? H,,7
Tem"erature ? 7I
Tensile Strength ? =/
Yiel4 Strength ? ;0
Glongation ? ,/
Aluminum 0.01%0
%ltimate Tensile Strength3 "si ? =>3000
Yiel4 Strength3 "si ? =03000
Brinell Har4ness ? ->
&ock)ell Har4ness ? B70
-./0 $arine 5rade Aluminum Alloy
Click on a Product to view details.
Sheet and Plate ,-./0%H110 or -./2%H110
or "ual3
Angles ! "# Ft $#%&'!
()))*
F-;G
Pi+e $#%&'!(,"* -ra.n
Seamless
F2;G
Sheet and Plate $#%&'!
())' or #%&,!())'
or -ual*
F7AG
Flat Bar $#%&'!()))*
F2<G
/ound Tu0e $#%&'!(,"*
-ra.n Seamless
F-<G
/ound /od $#%&'!()))*
F-HG
The Butt 1eld Fittings
and Flanges $#%&'*
FBG
Check up to five results to perform an action.
larger image Se2eral si@es 4ual certi5ie4
he follo'ing specifications co(er Aluminum -./2
OO A/>0P7
Chemistry "ata4
Aluminum? Balance
Chromium? 0*0>R0*/>
Co""er? 0*, ma6*
Iron? 0*= ma6*
Magnesium? =R=*-
Manganese? 0*=R,
&emain4er Gach? 0*0> ma6*
&emain4er Total? 0*,> ma6*
Silicon? 0*= ma6*
Titanium? 0*,> ma6*
Linc? 0*/> ma6*
$echanical "ata 4
'orm ? Sheet
Con4ition ? H,,7
Tem"erature ? 7I
Tensile Strength ? =/
Yiel4 Strength ? ;0
Glongation ? ,/
Principal "esign Features
This is a non-heat treatable allo 5or strengthening* It has 2er goo4 corrosion resistance3 is
easil )el4e4 an4 4oes ha2e goo4 strength*
Applications
Commonl use4 in the manu5acture o5 un5ire43 )el4e4 "ressure 2essels3 marine3 auto
aircra5t crogenics3 4rilling rigs3 TK to)ers3 trans"ortation e8ui"ment3 an4 in missile
com"onents*
Aluminum $ill Product Specifications
A(aila&le Forms4
Sheet an4 !late ASTM-B-/I 3 'GDG&A#-OO-A-/>0P.
0.01 Structural $arine
5rade Alloy Aluminum
Click on a Product to
view details.
Structural 23ual Angle
$'%')!T'*
F-BG
Structural Une3ual Angle
$'%')!T'*
F@G
Structural Flat Bar
$'%')!T'#))*
F@HG
Structural 4U4 Channel
$'%')!T'*
F<G
Structural Beams $'%')!
T'*
F7G
Structural Tee $'%')!T'*
F2G
/ound Tu0e $'%')!T'*
F@G
S3uare Tu0e $'%')!T'*
F@G
Pi+e $'%')!T'*
F-@G
/ound /od $'%')!T'#))*
F-@G
S3uare Bar $'%')!T'#))*
FHG
Flat Sheet $'%')!T'*
FAG
Flat Sheet ,0.01%03
Check up to five results to perform an action.
larger image he follo'ing specifications co(er Aluminum 0.01
707, Aluminum is3 b most an measure3 the most commonl use4 aluminum allo* It is
s"eci5ie4 in most an a""lication 4ue to its strength3 heat treatabilit3 com"arati2el eas
machining3 an4 )el4abilit* I5 that )ere not enough3 it is also ca"able o5 being ano4i@e43
a44ing a laer o5 "rotection 5or 5inishe4 "arts*
The main allo ingre4ients o5 707, aluminum are magnesium an4 silicon*
Physical and $echanical Properties
%ltimate Tensile Strength3 "si ? =>3000
Yiel4 Strength3 "si ? =03000
Brinell Har4ness ? ->
&ock)ell Har4ness ? B70
ASTM B/0-3 OO A-/>0P,,
Chemistry "ata 4
Aluminum ? Balance
Chromium ? 0*0= - 0*;>
Co""er ? 0*,> - 0*=
Iron ? 0 - 0*.
Magnesium ? 0*I - ,*/
Manganese ? 0*,> ma6
Other ? 0*,> ma6
&emain4er Gach ? 0*0> ma6
Silicon ? 0*= - 0*I
Titanium ? 0*,> ma6
Linc ? 0*/> ma6
Principal "esign Features
!robabl the most commonl a2ailable3 heat treatable aluminum allo*
Applications
Commonl use4 in the manu5acture o5 hea2-4ut structures re8uiring goo4 corrosion
resistance3 truck an4 marine com"onents3 railroa4 cars3 5urniture3 tank 5ittings3 general
structural an4 high "ressure a""lications3 )ire "ro4ucts3 an4 in "i"elines*