Building an Aluminum Sailboat Pt 2 - Construction Begins! | EP 219
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- Опубліковано 23 лип 2024
- Welding begins on our new 49-foot aluminum sailboat - starting with the very first welds, which Paul is given the honour of doing!! We explain how MIG welding works and show the process of assembling and welding frames and bulkheads for our Orion 49 sailboat through the use of regular and time-lapse video, animations and interviews at the factory in Makkum in the Netherlands. In this video, construction on our Orion 49 sailboat, Distant Shores IV, moves full steam ahead! Makkum is also a centre for traditional Dutch sailboats and we take you to the waterfront to Makkum Beach to see these lovely historic sailboats on the IJsselmeer (IJssel Lake).
#aluminumboat #sailboat #aluminium #boatbuilding #timelapse
0:00 Intro
0:33 Arrival at aluminum boatbuilders KB Alubouw
1:20 How-to weld aluminum - MIG welding for beginners
2:38 Tim Welds closeup MIG welding
4:09 First weld by Paul made on our new boat
5:45 Welding sailboat - setting up flat reference on floor
6:42 Makkum Beach waterfront life - historic sailboats
8:00 Welding a sailboat - setting up assemblies and welding
9:30 Bulkheads and assembly of frames
12:19 Next Time on Distant Shores
Special Thanks to:
Enksail Yachts - gebrvanenkhuizen.nl/?lang=en
Satellite Yacht Design - www.yacht-design.nl/
KB Alubouw - www.kbalubouw.nl
KB Alufrees - kbalufrees.nl
Members of the Distant Shores Cruising Club whose support make these videos possible - / distantshorestv
Partners:
Pantaenius Yacht Insurance: www.pantaenius.com/uk-en/?adi...
BRNKL Yacht Security & Monitoring: www.brnkl.io/
Brunton’s Propellers: www.bruntonspropellers.com/
Seldén Mast / Furlex: www.seldenmast.com/ Lewmar: www.lewmar.com/
Raymarine: www.raymarine.com/
Scanstrut: www.scanstrut.com/
Navionics Charts: www.navionics.com/
GN Espace Galley Systems: www.gn-espace.com
Highfield Classic Inflatable: www.highfieldboats.com
Oceanskies Yacht Registration: www.oceanskies.com/yachts/
Gebroeders van Enkhuizen Boatbuilders - gebrvanenkhuizen.nl/?lang=en
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About Paul and Sheryl Shard
The Shards are award-winning travel documentary television producers and videographers who have been sailing 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. Through their TV programs, UA-cam videos, articles/blogs and popular boat show cruising seminars, the Shards help anyone dreaming of setting sail to get out on the water and experience their own adventures safely and comfortably.
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For several weeks each year, Paul and Sheryl run Sail Away Weeks in beautiful destinations to introduce new sailors to the sailing lifestyle and to help experienced sailors build their skills. Check out weeks for power boaters too! See the schedule for canal boating in France in September 2022. Come aboard and sail or boat with Paul and Sheryl in some of the world's top sailing destinations for an unforgettable experience! For information on upcoming Sail Away Weeks see...
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Thank you for watching!
Sheryl and Paul
I love working with aluminum. Much more pleasant that steel. The yard looks amazing. Great video only problem is I keep wanting to see more. I have kept searching UA-cam over the years to see actual aluminum boat building videos and this series is the first I have seen with good details.
Thanks for sharing.
Thanks 👍 we'll do our best to get all the technical details into our upcoming films :-)
Shout out to the hardworking employees at the Enksail Yachts. I love a clean workplace. 👏
We agree!
so exciting
So amazing to see the manufacturing process really work. The individual pieces are collected into kits. The kits are welded together, viola’ now you have a bulkhead. I just love this stuff! (yeah yeah - nerd-Dave)
Couldn't agree more David! Its been a learning process for us with our first aluminium boat! Glad you're enjoying it!
Almost like Ikea furniture. Except with strength added.
Absolutely fascinating!
Great show today.
I am excited to watch the build from the overhead cameras. First aluminum build for me. And Paul, that was a great vertical weld. Good job sir! All the wood and plastic builds out there right now are not as exciting as your build. Keep them coming. Hey! maybe you could make a DVD set of the build 🙂 Linda and love our DVD set of your travels.
Cheers,
Jay
Glad you enjoyed it Jay! And thanks for your & Linda's support of our DVDs ❤️
Very coll... keep them coming!
Very exciting
Very interesting process, wow, thanks guys
Really interesting thanks for taking the video 👍
No problem 👍
Congrats! Looking forward to as much of the build as you can please share.
Aaah! Tim Welds wooo! I’ve devouring his, and others’, videos on aluminum welding. So prescient!
Excellent choice, excellent yard, I am sure this will be the best boat you ever had
Exciting project! Looking forward to seeing the completed boat 😀
Nicely documented, good start of the buildup by laying the first weld 👍 keep ‘m coming!
Such an awesome moment making the first weld on the new boat! Looking forward to more episodes on the build.
Nice very interesting!
Very cool. I love these videos. Aluminum is such a perfect material.
May you guys be blessed, great effort and videos showing the boat design, fabrication, and construction processes.
Thank you
Yes! More construction stuff please! I love seeing the process and learning about it.
More to come!
wow, seeing the old and traditional vs a new tech and materials build !
Please keep the build video coming. Really interesting all the little trick of trade to see!
Cheers warren
We are very excited for you both! Congratulations on the start of the next chapter. We'll be following along.
Thanks so much Eric! Its been very exciting so far!!
Congratulations! It's started. We imagine Paul is happy that the professionals have taken over the welding. We're looking forward to following the build. Cheers!
If I welded a seam on my own boat, I woild worry that that’s the one seam that will fail 😆
Seriously cool project
Thanks for sharing 😍🇦🇺
Fascinating! The precision and attention to detail is incredible!
Thank you! Cheers!
I have been working with metal for over 50 years. I have a small machine shop with cnc machines. It is good to see the application of 5056 shaped from 2 to 3D. Wish I were in line for the next boat. 20 years ago we made a 5 acre mushroom farm from this wonderful material, and no corrosion has taken place even with the strong fertilizer used in the growing process.
Very interesting video, thank you 👍
Glad you enjoyed it Maria
PAUL... IT IS FANTASTIC TO SEE THE ALL PROGRESS..... CONGRATSSS FOR YOUR WELDING SKILLS.... FAIR WINDS AND MY KIND REGARDS..... 🌷🍾🥂 CHEERS....
I love what you are both doing to your new yacht ⛵️ , this is going to be a great build and thanks for taking us along with you . 🐬🦋⛵️🦘🦘
Our pleasure Paul!
Looking forward to watching the process. Victoria BC
It's quite interesting to see how the process works! I'll be looking forward to seeing the fabrication continue. : - )
I’m thoroughly enjoying watching this process, please do keep making these build videos
Thank you! Will do!
Thank you for the excellent video. We almost feel like we are there with you. Very exciting!
Happy to hear that!
Another great episode of DS. Belated congratulations on 100K + subscribers. Thanks for sharing.
How exciting! I’ve been waiting for part two. I haven’t even seen the episode yet, just wanted to say hello, lol. Can’t wait to see this done. Ps thanks for answering my questions last video
Great video. I am looking foreword to the build progress. I have been enjoying the videos of RR2 for the past few months. Keep up the good work.
EXCITING!
You guys really are the pioneers of the Sailing / Cruising / Adventure travel UA-cam movement, having done this for more than 30 years now. Been following you both on and off for past few years and have enjoyed and learned so much just from your sailing episodes. Congratulations on start of your new build for DS #4. !
Wow, thank you for the kind words Michael!
Finally a good video on metal boat building process. 👍
Glad you liked it Bernard! More to come!
Good job Paul, now you can say you helped build your boat, way too go!!
Thanks 👍
Way cool. Would love to see some of their other projects
Thankyou 👍
You’re welcome 😊
Please don't hesitate to bring any fancy details to us. We really appreciate your attention to detail. Thanks
Paul, congratulation for the perfect start of your new boat! It's impressive how it looks complicated and at the same time so easy to assemble the structure of the boat. Definitely there was a detailed and accurate stage of design preparation. Now I presume everything will flow smoothly. Well Done guys!!!
Many thanks Giampaolo! I think the aluminum construction is flowing pretty smoothly.
The most perfect boat builder one can choose for a reasonable living on board vessel. If I would habe the chance house or boat I would always choose boat!
Great video, its amazing how far boat construction has come over the centuries but one thing will never change, the highly skilled boat builders.
Absolutely true Jack Stay!
That's next level cool if you can set the first welding bead yourself!!
Nice. Thanks. Being a welder, it will be interesting to see their fab setup and practices.
You bet! we'll keep on filming throughout the project!
Nice to see the boat coming along should see you both down in new Zealand in 8or 9 months
I welded steel at Quincy Mass.shipyard. Seeing all the tac and mig on so many parts, I have a new respect for aluminum. Then each has a chamfered to knock down the sharp edges, what a lot of patients in my book to complete. Awesome work on that fillet weld Paul, but a little more puddling ,think ~ little pillow pattern puddle, repeat 100 times. Thx guys
😂 thanks for the hints Wayne! I plan to do more practicing on the next visit.
We want more! 😍😛
congrats to you both , hipp , hipp , hipp
That was a great video, love seeing it all come together. We did the ultimate no no we sold our beloved O'Hara and bought a motorhome,
I am loving this! Makkum is a lovely place with so much expertise around. Happy to see you will be visiting Vlieland in the next episode. That is my favorite place on earth :-)
Can't wait SV Adma! The Frisian Islands are indeed gorgeous!
Very exciting I’m sure. Looking forward to following the build. I’m currently building a foam/epoxy trimaran on a sloping dirt floor in a temporary shed. Oh man what I wouldn’t give for a flat concrete floor! The amount of extra work I’ve spent levelling the job at various stages has made me realise what a boon that would be. Next time…
Good luck with your project Robin! And be safe with that epoxy!
Yes the measurement is critical. KB are constantly checking rechecking levels to see that the hull stays aligned but its so quick to do a check that its barely and inconvenience :-)
@@DistantShoresTV oh we keep our nitrile glove/3M dust mask distance!
What a fabulous 3D jigsaw puzzle. looking forward to design displacement, ballast etc.
Coming soon!
Wonderful... My first sailing video's we're your TV shows Distant Shores on AWE. Then I figured out UA-cam. Love you guys, much respect ❤️🌤️⛵
Wow, thank you! Its great having you aboard!
I can imagine the feeling of seeing a dream taking shape
You are so lucky to be able to build your custom aluminium sailboat.
Nice when all the pieces fall together
Proud to be Dutch (with Canadian wife 😉) and you choosing a Dutch yachtbuilder! So nice to follow the built of Distant Shores 4 and seeing you enjoying it!
Welcome aboard!
really like to see the process .. in detail if possible. Cheers from NZ
I'm a new subscriber and really enjoying the build videos. Very interesting and informative. Makkum seems like a lovely place and the boat yard is immaculately clean, tidy and organised. The workers are nice and engaged. Very reassuring. Looking forward to the new episodes
Welcome! Glad you're enjoying the build videos Ali : -)
Congratulations..
This is fascinating to watch. I love your excitement & like the design look of the Orion 49 a bit more than either Besteavar's. I'm sure that either yard would build an outstanding vessel- KM Yachts seemed quite competent too! What a great problem, deciding which excellent vessel will best meet your needs! Hahaha- please, keep the build videos coming!
Thanks for watching David! Its very exciting!
For your first time welding you honestly didn't do bad! They even had a speedglas helmet for you, good stuff!
The Dutch are civilized. This should be smooth sailing.
Just like a big model kit
Harika bir mühendislik. Çok güzel. Yapımında çalışmak isterdim, tasarımın başlangıcından suya indirilenekadar her aşamasında görev almak isterdim. Harika. Kolay gelsin.
Great engineering. Very nice. I would like to work in its construction, I would like to take part in every stage of the design from the beginning to the launch. Fantastic. Good luck with.
Well done! I liked DS3 so much for plan. But was abset a bit for its plastic hull. Now it seems to be fixed;
Hope you both get a chance to check out the Harbour town of Urk, only about 50 min drive south from where your DS 4 is being built. Worth a visit ! Spent a few months there while working on the feature film "Dunkirk" , check out the Eel fishery market at the main Pier. Some interesting historic boat building yards also in Urk as well as a very enjoyable town to walk around right next to the harbour and Marina.
Thanks Michael! Urk looks like a lovely village on the Issjelmeer. We'll see if we can get there one weekend! VERY cool you worked on Dunkirk! I bought a 4K-BluRay player just for that movie!
Hi Paul great video! Love Tims channel for stick welding process! Dusty from pacific art tig welding is also a great aluminum welder (hes from canada) has some of the best how to weld videos on aluminum. Has been a fun build to work on so far!
I'll check it out!
Of course more videos.
FYI good job on the first weld! I’ve been welding for a long time and have to admit that was a structurally good weld, lol. I would be proud if I were you actually.
Thanks Dan 👍
Congratulations, dear. I'm 77 years old, I've been married for 50 years... with the same woman, which is not very common, so it's a virtue that my wife and I celebrate with health each new day! I'm waiting for the 3 video of the construction. I still intend to build an aluminum boat. I really liked the concepts of KM. I like these particularities of choosing a life aboard this style, keel, etc. I would like to know the deadline for the complete completion and launch at sea with everything properly tested and working. I live in Brazil, but at these times the airliner is very useful there I love to fly...it shortens our time. Soon I will take a trip to Europe (Portugal) and I could even visit KM and see their "spectacular toys" I'm waiting for the 3rd video. My greetings to the couple. It is worth noting: It is traditional in the history of vessels to place a gold coin at the base of the mast! Tradition...today, the owner makes a TIG spot weld as the merit ! It could be the first solder point with gold...maybe ?lol...?! haha
Obrigado! The plan is to have the boat ready to launch July/August 2023 and be testing that summer. Our third video will be out in 3 weeks or so and Sheryl & I will be over in Netherlands again around then also. Let us know when you plan your visit. Gusto muitos Portugal amigo. Have a nice trip!
Howdy Sheryl & Paul... I don't have words to express how impressed I am with this vid... Notwithstanding very enjoyable, educational and entertaining... Looking forward to the next installment(s)... I worked on cathodic protection in a shipyard in Norway in my much younger days... So, I have some concerns about what are the shipwrights' plans for cathodic protection...? I just replaced my aluminum anodes on my prop shaft with typical zinc... The Aluminum anodes were fairly tore up after only about 3 or 4 months in the briney saltwater lake... A treatise on the subject of Cathodic Protection would be much appreciated if you can get to that stage of the build... Fair Winds...
Excellent idea Ron! I will add a video on "cathodic protection and issues relating to aluminum" to our schedule and shoot for it when we are over next month! Thanks!!
Really enjoy your videos!! I hope to one day also build an aluminum (or is it aluminium? 😜) Sailboat. Very brave that you did the first weld... Without much training!! That was funny 😂. All the best from Costa Rica
Thanks Yan👍 good luck with your plans!!
Great to see what modern digitization can do to boat building! Looking forward to see DS coming together. I heard on the previous video that there was talk about holes in the frames or stringers to allow for condensation water to get down to the bilges! Hope that was wrong as I believe that you will fully insulate the hull above the waterline and the entire deck area? Insulated portholes and hatches would also add to the comfort!
Thanks Lars. To clarify the limber holes were added as an insurance that if any condensation did come in somehow the holes would allow it to drain. The holes don't compromise strength and would be very difficult to add later - so the engineer drew them as a safety.
The portholes and windows will be insulated and that will help a lot in cold climates.
@@DistantShoresTV Thanks for clearing that up, however I would expect that the hullsides and deck will be spray insulated. The limber holes would surely be in the bilge? Would not expect any condesation between the hull and deck as that would become a problem!
👍
Being the skeptic I am I would always be wondering if MY weld would hold together over the years especially in a storm. It is really exciting watching any boat being assembled, this one will be done in record time compared to "plastic" or wood hull boats. THANKS!
Thanks Steven! I think that if my weld looked weak they would plan to run over it again to make it perfect :-)
Exciting Material, aluminum, for a sailing yacht. Light and strong and much thinner than wood. The only thing I wonder about, is the outside of the hull: Aluminum is much softer than steel and not very resistant to abrasion. How is the hull protected against sharp, high impact loads, such as sailing into a steel container or sailing into sharp rock?
Thank you Paul and Sheryl for sharing the boat build! I find this very interesting! Will you share any information on the pricing?
Our pleasure Uwe!
FYI the price is a bit more than €1M but includes quite a few "options" that I thought of as standard.
Hey, what do you guys think of the current Borreal aluminum yachts?
great choice of boat. did you consider buying a similar boat used, if so what designs?
did you also consider a new aluminium catamaran.
the dutch really understand aluminium, french also but i think the dutch would be more organized.
What a great start to the construction, and what a privilege to be allowed to make the first weld!
Having you practice first shows their commitment to quality, making sure your weld would be acceptable.
Those I-beam ribs will add some significant rigidity to the hull.
I probably missed it, however what decision was made regarding painting the hull above the waterline?
We will not paint the topsides above the waterline but will probably put cove-stripe on. Up on deck we are painting the cabin top and decks.
For anyone that doesn't know, welding generates tremendous UV. Looking right at it (in person of course) without the right gear can destroy eyesight. However, it can also give very bad sunburn. That observer should have also worn gloves for that reason or hid his hands. Just my opinion.
Thanks for sharing. I follow a few sailboat construction videos such as Tally Ho. Will the seams be fully welded instead of a few inches every few feet? A really nice boat to be. Any idea how long it will be before she is in the water?
Yes, absolutely! With Yalu you need to avoid overheating the seems and warping. So they tack it all together until the whole structure is solid. As I understand it, then they can run along the seems again with a continuous weld.
It was great that you mentioned Tim. How long time will the build take until you can take your new boat for new adventures?
Good question! The plan is for the boat to be launched in July 2023 so less than a year now!!
Amazing to see. When I was an apprentice, computers were not a thing. This would have been drawn by hand on film then blueprinted for the metal workers. My first aluminium welding was a dismal joke compared to yours.
Thanks Phil! Your comment on the old days reminds me I meant to add in a feature on the welding goggles. Years ago you got a super dark welding face shield that protected your eyes from the arc but you couldn't see through it until the spark. Now the glass is adaptive so you can see the scene as if you were wearing sunglasses. Then as soon as you spark the arc then it instantly changes to very dark. It made a HUGE difference!
Excellent! Appears to be a good choice for yacht builders. I'm still REALLY curious why your yacht wasn't a Garcia, considering their pedigree and infinite customizability............🧐
Thanks we are super-happy so far! We did briefly consider a Garcia but were concerned ocean performance wouldn't be good enough for us with all ballast in the hull.
@@DistantShoresTV Thanks for the reply! Understood
Any guess on how long until the splash day? Has to be at least 18 to 24+ months from May of 2022. Thanks.
Splash day is estimated as July/August 2023 so just one more year from now! Wow are we excited!!
what program is being used?
nicely done guys, congrats. looks a lot like Exploration @ Garcia, right? Any info on the final price?
North of 1M€
@@DistantShoresTV I see. thank you for your quick reply. If you don't mind, would you mind detailing a little bit about what made you choose this shipyard and not Garcia, for example?
Doesn't an aluminum boat get incredibly cold when sailing in colder climates? Does it conduct cold and corrosion with other metals? I just started watching your build. So maybe stupid questions?
cool, do they make catamarans?
I'm pretty sure they could build a cat but haven't done one yet. As a custom builder they could :-)
Congratulations , I guess I missed it , can you go back and answer a question ? what will the draft of the boat be raised ? And the draft of the boat being with the swing board lowered ?
She drawn 1.3 meters with the centreboard up and 3.6 meters with it down. She will be amazing upwind! :-)
@@DistantShoresTV wow ! Awesome !!
Why not a Garcia 45 or 52?