How Aluminum Sailboats are Made - KM Yachtbuilders Factory Tour | EP 202
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- Опубліковано 11 вер 2024
- Ever wondered what it's like to build a custom aluminum cruising boat? Come along for a factory tour of KM Yachtbuilders in the Netherlands where we get an introduction to the aluminium boat building process as well as the many types and models of yachts KM Yachtbuilders manufacture, including custom-built yachts like Skip Novak's new Pelagic 77. We get an up-close look at how aluminum hulls are shaped, see the stages of build and consider the pros and cons of aluminum boats.
⛵️ Sail Away Weeks with Paul and Sheryl Shard 🏝
Join Paul and Sheryl for a sailing experience in the world’s top cruising destinations. Get an introduction to the sailing lifestyle, build new skills, make new like-minded friends! Cabins still available for British Virgin Islands, February 20-28, 2022.
01:29 KM Yachtbuilders Factory Introduction
04:04 Bestevaer 53 Motor Yacht
05:29 Pelagic 77 Skip Novak's ice-class yacht
07:56 Keel types - lifting, swing, ballasted keels
11:04 Finishing Hall
12:00 Hull graphics by foil - wrapping instead of paint
13:46 Aluminum Hall - building the hulls
15:16 How Aluminum is Shaped
17:38 Benefits of Building a Boat in Aluminum
19:30 Welding aluminium fittings directly to the hull
22:02 Aluminium bollard welded in for extreme strength
25:21 Hull plate welding lifting keel plate
26:50 Swing keel Bestevaer 45
29:57 Woodwork and Systems installation
33:01 Designing a custom boat - feasibility
KM Yachtbuilders -
#kmyachtbuilders #aluminumboats #aluminiumboats #bestevaer45 #bestevaer53 #distantshores4
Equipment:
Pantaenius Yacht Insurance: www.pantaenius...
BRNKL Yacht Security & Monitoring: www.brnkl.io/
Brunton’s Propellers: www.bruntonspr...
Elvstrøm Sails: elvstromsails.com
Seldén Mast / Furlex: www.seldenmast...
Lewmar: www.lewmar.com/
Raymarine: www.raymarine....
Scanstrut: www.scanstrut....
Navionics Charts: www.navionics....
GN Espace Ocean Chef: www.gn-espace.com
Highfield Classic Inflatable: www.highfieldb...
Integrel On-Engine Generator: www.integrelma...
MG Energy Systems (lithium batteries): www.mgenergysy...
Ultra Anchor (35 kg): www.ultramarin...
Oceanskies Yacht Registration: www.oceanskies...
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About
Paul and Sheryl Shard are award-winning travel documentary television producers and videographers who have been cruising internationally since 1989 documenting their global adventures for television, social media, in books and sailing publications. They have sailed over 110,000 nm including 9 ocean crossings and are the producers and presenters of the Distant Shores sailing adventure TV series which is broadcast to 47 million households in 24 languages around the world (AWE, Nautical Channel, ACCTV, ShineTV). Through their TV programs, UA-cam videos, articles/blogs and popular cruising seminars, the Shards help anyone dreaming of setting sail to get out on the water and experience their own adventure safely and comfortably.
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Thank you for watching!
Sheryl and Paul
Very informative and educational.. Indeed aluminum boats have very unique advantages over the classic builds..Outstanding decision..
Thanks, Frans!
lookup pelagic australis on yt
@@DistantShoresTV Did you consider the Boreal 47 as well?
@@DistantShoresTV Just watched the Pegalic 77 tour on the KM channel..What a quality in all the details..Dutch builders are my favorites ..
Much much easier when there is any restrictions such as solas, class... Flag requirements etc. Basically just weldings!!
Having built aluminium boats myself I can see that man knows his business with no bullshit.
KM team deserves as much as publicity they can have. They are proper boat builders!
This man clearly is a sailor himself! He really knows his stuff!
I guess, there is no one with a better reputation for building custom/semi-custom aluminium expedition sail boats in the world. I think in 2013 three KM Yacht Bestevaer customs went through the NW passage (Bestevaers I know spontaneously that went through the NW-Passage: Novara, Morning Haze, SV Bestevaer II, SV Tranquilo (twice in 2012/2017 both times solo sailed, including freezing in, it's for sale currently, a super unique ship) .... than there are the expedition high-latitude one-offs like NanuQ, Quilak, Vinson of Antarctica .... ... the only thing is, the price. The asking price for Tranquilo is still 795k, used, build in 2006.
As a Dutchman I would say there are few yards around who can compete with KM yachts. Their experience supersedes many (if not all) of their competitors and whether you like a one-off built or a series yacht you'd always get the same quality. Thanks for sharing!
As a Belgian guy I totally agree ;-)
As an American I can say that the Dutch have a long and deep marine engineering and naval architecture reputation worldwide since before I can remember, and I'm 62.
Thanks everyone for your feedback on this.
As a boat builder by trade for many years, I still picked up some very good ideas from the tour! Very informative. I will be incorporating a couple of those ideas into the aluminum ketch I am building for myself in my retirement.
Glad it was helpful! Sounds like a great project, Ken. Keep us posted.
At 14:26 you can see a worker throw something over the hull, then watch the other guy look around like "what was that?!" Too funny. Thanks for posting this, very interesting to see a custom ship building facility.
Been a while since I’ve seen such an exciting, interesting and educational video. Huge shout out to KM for sharing what they do, it gleams expertise and the finished boats do look a million dollars (which they probably are 😀). Just love the attention to detail with resulting practical value. I wish both of you success in the process and look forward to being part of the UA-cam journey. You got me hooked now!
Glad you enjoyed it! Yes a big shout to KM for cooperating with filming and allowing us access to their behind the scenes....
Hi Paul and Sheryl. It is so exciting you are getting a new boat. We had an opportunity to meet the owner of the boat stuck in the ice (time 3:04) in Corner Brook Newfoundland as he overwintered in our marina (Bay of Islands Yacht Club). This picture was taken when he was frozen in the ice in Baffin Island when he overwintered in the northwest passage in Canada on his first circumnavigation going west to east (opposite to most cruisers) single-handed sailor. My husband was on the boat and it was amazing!!
The more I hear, read and see from KM the more impressed I am. Looking forward to seeing your new boat!
Strong strong, boats. Most are 3/8” thick plate 6061 alloy. He’s smart because doesn’t paint most of the boat due to oxidation that eventually creeps under the epoxy . . Dereckter built the americas cup boats out of aluminum. I watched many boats built by Dereckter and this guy knows what he’s doing.
Thank you guys and your host for an excellent video - I was engineer on two different aluminum commercial seine boat on BC's west coast - One was built by the owner of the boat works to show what could be the ultimate decked out fishing vessel - the build of these vessels is obvious much different than those of yachts but so enjoyed the depth of how production of these vessels is done. I share your excitement in your new adventure - following as always. Everett
We appreciate your expert comments, Everett! Thanks for following.
The only thing better than a lifetime of learning seamanship is taking that knowledge and incorporating your ideas into a custom build. I can’t wait to hear your criteria for the perfect sailing yacht. I can’t wait to discuss what I’d like to see in my stateroom? 😂😂 Kidding aside, I’ve never seen that level of detail detail in a cruising yacht.
We're still working on details of the design but are filming the process to show you what we come up with.
So the premier sailing couple are having a custom aluminum boat made by the best yard in the world? And we get to watch? Incredibly exciting!
(My blue sky fantasy is to have KM build a 70' aluminum cat to be used by explorers and scientists around the world, especially in the high arctic, for the next hundred years. )
One of the best youtube videos I have ever seen. That woman also asks great questions.
Great stuff, I loved it when Mr. KM was explaining the 20mm keel plate, saying he had tested it many times himself, accidently of course. The transducer protectors, also a very nice feature.
One thing to take an interest in is the toughness of marine grade aluminium. There is no comparison between the marine and standard 6061 plate. Marine grade has a huge degree of “springback” when bending or rolling. This is where the skill in driving the English Wheel is so necessary. The comfort here is in the degree of strength your hull will have in contact situations.
Thank you for posting. This was extremely informative on where and how aluminum yachts are constructed. Our dream is to get one someday so we can go anywhere in the world.
I'll own one of these.....as soon as I hit Powerball!!!!
We’re spending the evening watching a pile of your content. Just wanted to say thank you so much for your work. You have been a great inspiration to us since 2015. And counting!
Wow, thank you guys for the kind words! Glad we can give you inspiration. Its great to have you aboard!
They english wheel the entire yacht. Dear god this is a talented work force.
That is an amazing amount of work.
Yeah these boats are very much an art. Those tradesmen must be impossible to find in this day and age.
Notice how the welder is sweeping the floor between welding, good management and good employees. Organization of shop, clean floor, good indication of excellent work!
WOW! You learn something new everyday! Thanks for sharing this!
So glad you enjoyed this video, @Sailing Avocet!
Wow...these boats are next level...you are going to explore areas that very few others get to explore! Look forward to following you along on your upcoming adventures...
As someone whose only experience with aluminum vehicle construction was building Cessna jets, it's pretty interesting seeing just how much heavier built the boats are. All of the ribs and stringers in those jets were made with metal sheet that was maybe 1 or 1.5mm thick and stamped/pressed to shape. And they weren't welded, just riveted.
Also, it seems almost strange that you're not getting another southerly, lol.
Can you really eyeball the thick of those aluminum hull? Is it around 5-6mm as they mentioned?
@@mikexhotmail I can't actually tell precisely how thick it is, but it's certainly multiple times as thick as the sheet metal I used when building Citation X wings or Citation Bravo/Encore fuselages.
@@FlesHBoX Thanks. English wheel the sheet in to a nice uniform curve seem to be very tough job...more like an art.
It's amazing what can be done with recycled beer cans
Thanks so much for an excellent video. Plastic composite boats have a lot of good features, but releasing that much plastic into the environment is a major negative. Aluminum is highly recycled and recyclable, and also highly durable for use in boats due to its inherent corrosion resistance. I'd argue it's a lot greener overall.
These KM boats are built almost like workboats. Should be very durable.
Great point! Glad you enjoyed the show :-)
My favourite video of yours of all time. Now I want one of them as well! I always knew the Dutch are quality boat and yacht builders, and this certainly proves the point. Wat ‘n wonderlike sterk boot. Ek weet waarvan ek nou gaan droom! Beste vaar inderdaad...
I WANT ONE!! Now, if I could just find a few million dollars. I have always said that aluminum is THE boat building material when properly done. I worked as Captain of an all aluminum 70 foot Morelli and Melvin power cat. Wonderful. I met a couple that had circumnavigated twice on an all aluminum sailing cat. I asked “ what about the penny in the bridge water thing” ? They laughed and said ‘ what bilge Water. Everything is welded and no through bolting of anything. Hmmmm never thought of that one! Absolutely amazing and beautiful. THE way to go if you can afforded it.
Where can you go from a lovely Southerly like yours? Of course to an all aluminum custom yacht!
Thanks for this valuable feedback and kind words, Fred.
Amazing educating vlog about KM yachtbuilders and aluminum construction, thank you !
Glad you enjoyed it Mehmet!
They do look like beautifully built boats.
How exciting!
I've been once in an aluminum boat under the Spanish sun... Oh my goodness, how hot there was inside. Here ends all I know about aluminum boats 😁I hope they are worth it. Good luck with the new project 👍
Hello, it could be that that yacht was not insulated properly? We use a PU-foam that works both ways in keeping the cold out but also the heat. Overall, a properly insulated alu yacht should be cooler compared to GRP since we add extra insulation.
Have had multiple "Plastic" and aluminum boats, no insulation. No sweat, A/C and furnace managed the temp inside when needed. Just watch for stray currents from dock and other boats. Would choose aluminum again...
Amazing....I've been following KM for some time already, as they build the dream I have every single day!
This was great! And what a great virtual tour that was, we got shown so much detail and given so much info!
The best decision one can make: KM-Yachtbuilders. Delivers all needs spot on all demands. No better choice one can do! Congrats.
Thanks for your feedback!
The KM built boats with more rounded hulls are a little easier on the eyes than those built more angularly. No clue if there is a performance advantage, to one versus the other, but KM sure passes the eye test. Kind of like the difference between an F-16 versus an F-117.
Fantastic boats!
Good luck on the boat order. The builder looks like they know what they are doing and attention to detail is really good. It also looks like the owner is very proactive
Great video ! These aluminum boat will last for sure ! They look very robust, but are we in the same budget $ of fiberglass and a lot of glue ?lol
Super informative and what an amazing company. You most assuredly feel very safe floating around in one of these. Looks like a sailboat but built like a tank. lol Makes you just want to ram something. Or maybe say at anchor, Put up a sign that says drag in to our boat at your own risk!
This is a really great video. Thanks for sharing.
Very interesting and exciting, thanks to you and the builders. I see why they have been successful.
Wow, just mind blowing boats! Strong as OX!
Very excited for this process.
Us too! Glad you enjoyed the video, Craig.
Wow ... what an insight, great video, thank you so much! 😃
Great, KM Yachts amazing
Looking forward to this process!
Thanks a lot for a very interesting interview! My opinion is that aluminium is the best material to build a sailboat. Aluminium boats have a very long service life. Material is energy hungry but we need to keep in mind the service life and the fact that the boat can be recycled in the end.
My old classic aluminium yacht was built in 1967 and she is still rock solid even though she was badly neglected for years. For the new boat under the design there wasn't options for the building material : )
Smart engineering, what an amazing boat. love this vid thank you.
Brilliant place to get your next sailboat. Really nice details!! ✌🏻💗😊❣️
I do have a idea for a rig, it's like the normal bermuda but with a mast shaped like a ladder that has 2 booms with their mounts at 45° away from rear on both sides. This would make the boat faster down wind and more configurable.
Interesting idea.
They make amazing boats.
I found your channel from another channel.. I exited that channel, just because there was no one explaining what is going on.. Good to hear your voice.. I will explore more on your channel.. Thank you!
My Dad loves your channel!
Nice video, i can recommend KM out of my own experience.
Well considered Quality built to last, something we see less and less of in all industries unfortunately. Superb to see and an exiting time for you again. 👍
Oh wow!!! Stunning.
The Dutch know how to build boats.
Fantastic project. Metal art.
I agree these guys are artists with aluminum 🙏🏻
aluminum is awesome
The boat made by dreams. Coming from wooden boat ancestors, and the glass boats just never were anything more than utilitarian.
The new aluminum trend, with modern fabrication design and manufacturing... the new world of aluminum boats is more than a little exciting. Modern electronics, power generation...wow !
So glad you are enjoying this series of our videos, Peter! More coming soon!
Excellent thank you.
Those boats are badass!!!
Exciting stuff very interested in seeing this project, I really hope your able to catch the build process in video thanks for sharing 👍👍
You bet! So glad you enjoyed this video. More to come...
That was so informative, I wish there would be a series of videos that follow each step in the various processes. I could binge watch. Great show KM.
The only thing to take really care of is the electrical system and how it is isolated from the hull like consequently using double-pole wiring. I have had an aluminium boat for 20 years without any problems. The many locations where steel bolts met aluminium like for the lids of the cockpit lockers or the ones for the standing rigging did not show any corrosion after all this years. KM seems to be highly qualified and being aware of any problems that could came with aluminium which is IMHO the best material for boat building.
Hello, our yachts always have an inverter and double-pole wiring. We try to avoid steel where we can. For example the bolts and hinges on the cockpit lockers are aluminium and not steel. When we can't avoid it, for example, with a winch base plate or stanchions we isolate both materials from each other with POM.
Thanks for answering this question, @KMYachtbuilders.
Now this is what I call informational...well done.. giving us insights to boat building procedures and decision making attributes is most interesting. The "why" and "because" is what really helps us (me) to follow the dream we all (who watch sailing channels ) have. Words are not enough to complement the wonderful job you both are doing. I look forward to watching and learning more of the discussions behind the reasons. Kindest regards from Portugal. Felix
Thanks for this wonderful feedback, Felix! More videos to come...
Very exciting project. All the best you guys
Excellent video. KM builders have an excellent reputation. I am looking forward to your choices/feasibility videos.
Hi there. What a informative video and really beautiful yachts. I know you want to have the yacht custom built for you have Garcia yachts been considered by you. The 53 is a lovely yacht. I know they are coming out with. 60 but I’m sure it will break the bank. Cheers to you both. X
Dreaming great stuff
THANK YOU For sharing this video with us it's was excellent video👍
Glad you enjoyed it!
outstanding choice
Thanks for the factory tour
Very cool.
Happy birthday, Paul!!!!!
Brilliant, love it, I am very interested in your project.
Thanks for the great video presentation.
Glad you liked it, Bernardo!
I hope KM will meet up to your dreams. The Bestevaer 45 Pure has been on my wish list for a while!!
They seem to really listen to our criteria and are working on a design that will fulfill our dreams.
Our daughter Natasha and her husband have commissioned a Van R5 catamaran from Van Yachts in Hellevoetuis Holland. It too will be all aluminum. Hope to splash in 2022. We’ll be kept mainly in the Med.
We wish Natasha and her husband all the best with their exciting new project and will watch for them in the Med.
@@DistantShoresTV Thanks, by the way are you still members at PCYC? Helen and I were members when you were building Two step in the yard. Paul and I worked together on the dock committee, and you and Helen were on the first mates. We are still non resident members, as we live in FL. We spent 7 years in the Bahamas, betweeen Eleuthera and Nassau.. We’re off to sail the Abocas on Wed, this week. take care, André
Great! Have you ever looked into the Deerfoot yachts, by Steve and Linda Dashaw? They had some great long distance crushing yacht ideas back in the day.
The Dashews were great designers with a philosophy of safety first, then reliability, comfortable cruising, and finally speed. The Beowulf class which followed the Deerfoot class would be a better comparison to KM Yacht builders because it, like their subsequent FPB series were of marine aluminum construction while the Deerfoot class was the last of their fiberglass boats. That said the Deerfoots enjoy a strong following.😎
Very interesting choice in boats, great to “treat” yourselves to a custom. North West Passage, Hebrides and Northern Europe is beckoning. And maybe down here to NZ, Stewart Island, Fjordland, Auckland Islands and Antartica!
Thanks! We had hoped to be coming your way last season but the pandemic put a halt to those plans for the time being but we will see you sometime!
Miss ton see how the insulation of the hull and deck are done and the material used and applied. AAlso looking forward to see the rig. KM yachts are awesome, you're lucky to work with them!
Paul & Sheryl,
What a wonderful journey of design and construction combining the collaboration of a highly experienced world cruising couple (30 yrs + many thousands of miles of cruising in four custom boats) with the talents of a premium aluminum custom yacht builder, constructing yachts of multiple keel types to operate under the harshest conditions.
I’m interested in you sharing your design considerations as you embark on the adventure of construction. One question I have is about the decal application which functions both as decoration and anti-fouling. How will the cost, durability and yard availability compare to traditional. bottom painting on a 7 year replacement schedule? How is anti-fouling to be addressed inside the keel trunk? 🤔 The film must have exotic ingredients to resist marine growth adhesion for that long …… Teflon, biocide? If it works as implied it will provide huge savings in labor and environmental impact in the long run. ‘
Thanks for a great, informative video! 👍
WhooooHooooo! About freakin' time!
Excellent production value, well done.
Great video, thanks for sharing.
PARABÉNS, VOCÊS DIZEM CONSTRUIR BARCOS, EU CHAMO DE CONSTRUÇÃO DE NAVE ESPACIAL, CADA UMA MAIS FANTÁSTICA QUE A OUTRAS, E AS CABEÇAS QUE PROJETAM, VALEM OURO.
How nice to be involved in the design process...where you can actually ensure you can get to things to fix them in the future. That is my biggest beef with production boats...they put them together without a single thought about being able to get to things that need to be fixed in the future.
How right you are!
Hi! Awesome video. I am wondering if you have looked into the insulation and paint protective systems of your future boat. I am currently building a 38ft Aluminium yacht and I am trying to figure out 'best practice' for insulation and paint protection. My understanding is that KM spray foams the interior. However in some photos Ive seen they spray below the water line with paint. Some experts mention that the interior hull should be left completely bare so that the aluminium can create its protective oxide layer. However others say that in 'wet' areas it should be painted. Other experts mention that aluminium boats are generally dry boats (Im not sure why). Additionally, Building Odyssey has put in a Mascoat sound insulation product. I actually had the tech rep come out to the boat and show me the product. Its extremely expensive. So my question is, do you have a spec you are going for with your boat in terms of insulation? (Sound, Thermal and Paint Protection?) Thank you!!!
This was just amazing. If I'd have the funds, I would go with this manufacturer as well. Bestevaer boats has been popping out on my research from the very beginning.
As for your project, I want all the information. Like right now. Or yesterday! 🤪
Good day the shard’s,
What a great experience for all of us to get to see your journey. Paul do you have plans to add the integrel solution on this new boat. :-)
Wishing you the best.
Great video and discussion, really enjoyable
Glad to hear it!
I sailed on a 1914 North Sea Pilot Schooner that was once named the "Bestevaer." Built near Amsterdam in 1914 as a Dutch North Sea pilot schooner, the Sailing School Vessel (SSV) Tabor Boy originally carried the name Pilot Schooner #2 and was engaged in pilot service until 1929. Pilot schooners housed on-call pilots (guides with local knowledge), transporting them onto large visiting ships to help their captains navigate safely into port. In 1929, the schooner was renamed Bestevaer and sailed as a school ship for the Dutch merchant marine until World War II.
Bestevaer was returned to Holland after the war where she was refit for use as a private yacht. She was then sold to businessman Ralph C. Allen in 1952. Mr. Allen had the vessel sailed to the United States and, two years later, presented her to Tabor Academy.
Thanks for this great story. As we understand it, the name "bestevaer" was a nickname given to Michiel Adriaenszoon de Ruyter (24 March 1607 - 29 April 1676) who was a Dutch admiral. Wikipedia says, "Widely celebrated and regarded as one of the most skilled admirals in history...Often dubbed a Dutch folk hero, De Ruyter is one of a few select officers in the history of the Dutch navy to hold the title of the lieutenant admiral (Dutch: luitenant-admiraal). Reportedly beloved by his subordinates and seamen, De Ruyter was commonly nicknamed Bestevaêr (Middle Dutch for "grandfather") during his service, a nickname that is sometimes still used to refer to him in Dutch media. It is also a term used for a good seaman, I believe.
@@DistantShoresTV That's the story I was given about the name. We had a picture of a painting of him in the deckhouse.
@@DistantShoresTV Yes, it also means something like Beste Vaarder (best farer).
Very interesting.
I would like to suggest an episode about "Where can I anchor my boat?". How do I know if anchoring is permitted at a location? It would be nice if you could cover France. Thank you. Your channel is great!
Wider and longer costs more to dock, if they have a large enough dock....aluminum hulls hold their value better in most cases....avoid stray electrical at dock...
Hey sounds like your building my dream boat :) love to see what you choose
Which among the naval architects/designers will you base your new boat on? Is it to be a Bestevaer? Koopmans? I am looking forward to following the process with you. Thanks.
@André Thanks. I am aware. . Just didn’t want to a) misspell Gerard Dykstra’s name or b) look up spelling on the fly ;-)
Have you considered Kanter yachts in St.Thomas Ontario. I was amazed at the quality of their workmanship.
Yes, we spoke to Kanter Yachts in St. Thomas, Ontario, several years ago. We are from Ontario and they do great work.
Is there a greater threat of lightning strikes or damage from a strike when sailing an all aluminum vessel?
I know them. They can make some nice boats. On the other side of there shed Feadship Makkum is located where i worked a while. When Novak let’s his boat build there, you can be sure you get quality.