HDPE (High Density Polyethylene) Boat Build Part 1
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- Опубліковано 4 вер 2024
- In the spring of 2023 my dad and I started building a boat out of HDPE or High Density Polyethylene. I had the idea in my mind for years but couldn’t find the right size and wall thickness of pipe.
Finally I acquired the correct pipe and it didn’t take long to get started on the build. I have enough pipe to do one small “Test” boat to work out all the bugs and another larger boat as a final project.
The pipe was fused with a heat plate and the ribs and transom were hand fused with a heat gun and HDPE rods. There has definitely been some learning curves on this project, hopefully we get them all worked out before moving onto the bigger boat.
Hope you enjoy! Stay tuned for part 2 and on, and like, share and subscribe!
Plastics fabricator here, I love your ingenuity. We use similar methods, for our constructions. We recently built a barge out of HDPE. I salute your efforts 😊
I built HDPE water tanks for our bus project. I would highly recommend getting a proper plastic welding hot air gun - they are temperature controlled, and the feed nozzle puts the heat exactly where it needs to go, so you don't get the distortion. The manual feed versions are only a couple of hundred bucks, and are absolutely fine for limited production like this.
One thing I tried on the second tank was partial depth cuts at the fold lines. The cut went to the outside of the tank, folded, then backfilled with a bead of filler rod - something similar might help forming around the bow.
I did buy the proper tips and a much cheaper heat gun that is of appropriate wattage and has temperature control. Watch the part 2 for more info
@WoodLander- just watched your second video. My guess is that your standard hot air gun doesn't push out anywhere near as much air as even a buget hot air welder does - your "inches per minute" was way down on what I was getting, which will also be why you're getting so much distortion.
The other thing is to buy the filler rod by the roll if you can, probably 100' in your part the world, instead of those chopped up lengths. I got mine from the local fishing boat supply outfit, as they're always repairing floats and fish bins etc.
It’s far cheaper that way AND it means you can use the speed nozzles included in the set you bought. Those work really well, far faster and tidier. The only places the heat goes is into the vee of the weld and preheating the filler, they move almost as fast as you can push the rod in, and the weld gets mashed down nice and flat by the heel of the nozzle - provided the hot air source is up for it.
What you're doing is obviously working and will be plenty strong, but like any tools, you get what you pay for. The less money I spend, the more time on the job I spend wishing I'd spent more money, is how that's usually works out for me 😂.
Anyway, it's a cool project, and I'm surprised more people don't do something similar - the boat will be bombproof when it's done.
@@petercroft9895thanks for the info. I do plan to buy a proper extrusion welder after this. I think I will start making all kinds of things out of HDPE.
I guess I just wanted to see if I could do this as cheap as possible. I hate watching DIY videos where the person completes a build with tools and materials that most people don’t have and can’t afford.
This is definitely an experiment to see what is possible.
@@WoodLander-but you used a CNC and a CAD program..LOL
@@Jordan-sy7my Fusion 360 is free for hobbyists and there are plenty of affordable CNC services out there. You could always make templates and hand route as well.
I'm 71 and have loved working with my hands on steel and wood since I was a teenager. You take that to the highest level. Thanks.
Jig and clamp making Ingenuity at it's finest! Thanks for Great Ideas! Happy Floatin'!
I would be thinking about filling the inside with that expandable spray foam to displace any water that may leak in. I loved that you had an idea and took up the challenge to actually do it. I hope it works out for you. Even if it doesn't, it's a great learning experience. And even if it doesn't work out, please tell us about it and why, and if you would / would not try again.
You bet. I will document the whole thing. Should have a new video out soon.
Expanding foam absorbs water and becomes too heavy to drag out of the drink. Putting waterproof plugs into the topside so it can be turned over without the plug in, thus drained. Speaking from experience.
@@jackrichards1863 Thanks Jack.
@@DavidM2002 reasonably gracious of yuh! There are little rotation molded boats we have one, those were done with foam filler. Outer is HDPE .
@@jackrichards1863 I agree. I’ve worked in the marine industry for some time now. And foam does soak up the water and become very heavy. I will be putting plugs in the pontoons as well as the transom.
Randomly, your video came across my feed. Having previous experience installing utilities. Was on a crew to do a water diversion project for a lake flooding vacation homes. We used a chainsaw to cut 36"x 3/4" HDPE with dish soap as the bar lubricant. Using standard pipe fusing practices, we needed to keep the fusing joints as clean as possible. HDPE is a very durable material.
over six hundred views No one is hitting the like or subscribe. It's free to do. It might encourage him to make more videos.
0:16
Adding the v bottom
To the two toons greatly increases your bottom clearance.. by 400%?? From 8 inch to 2 inch. Of course guessing.
For my 40 ft toon ,So let say I use 6 ( 12ft ttl) two ft diameter pipe to
Cover it with 14ft deck leaving 2 ft channel in middle
2×2×0.782×6×60×40
45,043.2 gross displacement
7507 each pipe
30,029 gross
4 piper
15,014
2 piper
But I want the draft
I maybe return
One lb sq ft aluminum deck frame
187 lb displacement
Per ft long of pipe
2x2x.782
= 3.12 x 60 lb
18 lb per ft long pipe
1.5 in thick x 40 ft 753 lb
10 % draft per pipe
2.4 inch
Very interesting build ! Impressive 😮
Nice. I hope you release a Part 2.
Your methods look very practical and ingenious. Subbed, When is the next episode?
Just posted a photo
An excellent idea that has come to mind for myself numerous times. The heft of HDPE pipe of such sizes is the first problem I had reservation about. But you did the right thing and proceeded to build. In the industry we always had to shave the pipe as smooth as glass, wipe it with acetone or isopropyl alchohol. then quickly attach both ends to the heating plate. Mention this as the knowing people say it's how you ensure a gasproof joint that will not fail.
Then the heater is removed and still in the clamps it is immediately pressed until the bead is is squeezed out evenly..... I do not doubt that your work is succesful however.
I expect a frame will need clamping onto the pontoon for the engine support? This will be the most eerily bouyant tub in my experience with little rotation moulded HDPE boats. Those were welded an inner and outer together and filled through a hole with expanding foam. Dangerous to board in the water being so slippery when afloat but the load bearing ability is just incredible. I figure the material is lighter than water? I'll follow with eager attention. I believe the design is exactly the best style of hull to make from this durable and resilient material. If only boats like this could be made from plastic recycling of plastic junk eh?
I believe they can be made from junk plastic but it would be a tremendous amount of work
Might be slick when wet but that is why you apply something like the no-slip liners you can put down in a bathtub. Seen it done on even fiberglass hulls because once painted they are slick as ice too.
@@SilvaDreams yeah I mean the boat is so slippery in the water.. not to our feet or hands. Like as I step out and my weight centre goes past the gunwale it tries to launch off shore like a greasy pig. Thanks for taking an interest and reading my article 😏👍👍😄
@@WoodLander- yeah just dreaming for the dreamers there. Eco sensitivity for eco sensitive. 😏
Love to see part 2. I have welded this before with a machine on tracks
Check out part 2
Isnt it cool how we can just create things like this. It's a shame that the act of doing things yourself is so rare to come by these days. There is no difference between this and our ancient ancestors creating boats and canoes from burning out the insides of logs. Just as them you are mastering the materials and tools available for the time
The act of doing things became rare when they sent all of our jobs to China and sold kids a false lie about going to college for a degree so they can have a desk job that eventually gets replaced by AI
Looks great. I want to build one as well. Looking forward to your next video!
Check out part 2
Sears learned there lessons with plastic boats years ago, better luck in your adventure
Nothing wrong with HDPE plastic. Has been the industry standard for whitewater kayaks for decades now
I had the same ideea more than 20 years ago. But instead of using hdpe pipes, I used my old Metzeler hypalon boat as captive plug and it worked quite good
I have thought about this for some time. I always wanted to use HDPE because it is so versatile. But I also considered aluminum. I even saw a video of a guy who did this with aluminum
Intresting project - I spent a few years working for a UK Rib manufacturer designing and making Hyplon tubes. A couple of coments below mentioned adding expanding foam to the inside, with Hyplon tubes we used to add bulkheads and pressure relif valves.
fill tubes with empty 2lt coke bottles = safety flotation
Such a great notion. Make sure each lid is on there well tight. Positive bouyancy for decades.
Great video of.a great build, i think we are all waiting to see your next video! Good luck!
Check out part 2
Good job. Will do a very heavy for its size boat but bullet proof and no maintenance. Subscribed, this building system deserves to be learn.
Definitely following this build
Check out part 2
@@WoodLander- oh hell yeah!
Pretty neat, subscribed to see the results!
Check out part 2
Well done , great job.
Awesome project
So you guys literally made the boat from Family Dollar that comes with the military action figure that your kid puts in the bathtub and you made it adult size pretty cool keep up the good work
I have worked with wax and thermal plastics and have only a few ideas. First I love the idea you have. Try several heating irons in a fire becoming red hot. One in your hand adding filler plastic. Tack around the skin and tack it big. Weld six inches and change location. Don’t blow heat at the seam use the heat from your irons. Keep the iron hot. Exchange regularly for wet sticky welds. After cooling heat and press mesh wire into anything that you like to reinforce. Weld shapes of metal together and heat them then press them into joints to prevent cracking. Not that I think it’s necessary or you should do different. I love the boat! I just want you guys to know.
Looks pretty good I have thought about doing this for years just been busy. Hope it works out for you
That's a really nice boat
Sum great ideas there
Brilliant Idea well done, Subscribed.
really looking forward to a part 2 of this, I have a few questions and perhaps a proposal for you!
I’m open. What have you got?
For the next one, you don't need full discs of HDPE inside for baffles. Cutting two pieces and leaving the center hollow will keep the round shape and probably be easier to fuse in there
Fill with expanding foam so even if it cracks it will float
Would like to see the fusing, did you use a standard heat gun? You have an opportunity to come up with a simpler design, like a catamaran. You can probably heat the bow of the tubes and squeeze them closed with a couple clamps made from 2x4's.
Check out part 2
Use the same program to cut out plywood to laminate and screw to the transom
we are waiting for the nexts steps thank you
Check out part 2
Cool build!
interesting build! i would have put something solid all the way around the "rib" on the underside, like a solid piece of roundbar going around all the way from one side to the other just for extra reinforcement to keep all pipe pieces together..
It is very common to learn by the end of a project .
Trust me when I say I am learn throughout the process
You need a plastic extruder gun to do this properly, those welds aint no good. And for the pipes you need a buttwelding machine. Do you scrape the weldingsurface before welding? You did cut the pipe nicely but did you clean away all the oil before welding? your beads look like they have a lot of dirt in them wich is a big nono. If you have done this correctly you could drop this hull on concret from the height of 5m without anything breaking. You should test this before going out to sea with it.
An option for the cylinders would be fiberglass liners , how they re-line plumbing pipes .
Cool experience
How brittle will the plastic hul be in the sea where the temperature coul be down to 5c deg or lower ?
Best wishes with your project 👍
Excelent plan ¡¡¡
Just found this, so my advice is way too late. Invest in a strip heater and try to keep all your welds on the suports. You can get a tacking tip and speed tip for your welder, which will give you a stronger weld as the slower you go will release more oil, reducing the penatration and weakening the weld. A vee scraper can be found at most paint suppliers and acidtone for cleaning the welding rode and weld surfaces after scraping them. Remember to rescrape when adding a new weld over an old one. The strip heater can bend nice 50×50 angle witch can be used for stringers.
Woodlander, for welding heavy HDPE plastic, could you use leaser welding, as it use controlled intense light for heat???. just a thought, what do you think? is it feasible, thanks Allan
I would have sealed off the different sections so that any leaks in one of them wouldn't sink the whole boat.
Do you think you could expand more on the joining process, I heard you say heat plates but that didn’t paint a picture in my head, I know they’re all done now but if you could just show the equipment and how it works
Cheers
You bet. I will do a live example of the butt fusion for the pipes. But for now check out part 2
I built and rebuilt a fibre glass boat on an inflatable dinghy as a form. First build was ultralight and planed off with three horsepower. I then rebuilt it for strength and it got rather heavy in the end. Curious to see how this works
at joints - something like Plumbers tape or metal screen - melted into joints ?
Very cool and alot of hard work i 1 video. do you mind sharing the price of material? Looking forward to part 2
I salvaged the pipe for free. I have put about $500 in material so far. I estimate around $1600 USD for the material to build a 16ft boat.
how/where were you able to acquire the HDPE Pipes and sheets for making the hull?... I have been looking and contacting companies trying to find some
Theirs a company in Co. Donegal who make fish farming work ribs style boats up to 10m a 6m costs around €70k but their all plastic welded seams and built like a tank
I would put an electric motor on it torquito or e propulsion. Cost breakdown would be nice
Interested to know how much it weights
Better question, why build a 500 lbs boat ancor out of plastic??? Why not fiberglass or carbon fibre?
Alcatraz escape boat
Cool
Pipefitters gone wild
I DID hit the like and subscribe.
whaete is the materials source for that pipe? I have been looking for years as well 😅
This thin wall pipe used to be used for irrigation for years. Most HDPE pipe used now a days is much thicker wall. You can try farmers and see if they have some old stock.
Do an 80 seater??!!
5194 Hand Mill
How much does this boat weigh? Hdpe is not light
Do you think it's better than fiberglass Thinking about doing a pedal boat and im over fiberglass
I think it's petter for several reasons
More flexible without cracking
It's easier to fix
Recyclable material
And the best ever as i read it's antifouling material so no need for bottom paint or cleaning
Also i believe it's less expensive than fiberglass
Also working with fiberglass is dirty and hard
I have not worked with fibre glass. But from what I know about it can be a pain. HDPE has been relatively easy to work with. It takes some practice but it is not hard to learn.
Maybe I missed it in the video, whats the material cost so far?
So far I am in for $500USD. But I got the pipe for free. A 50ft length of DR 36 HDPE pipe is about $1000 USD. So total material brand new would be around $1500 USD.
How does durability of hdpe compare to umhw? I'm building a aluminum jet boat for extremely rocky rivers. Everyone I've spoken to says umhw only, I have access to hdpe for half cost of umhw.
Obviously UHDPE Ultra High Density Polyethylene is stronger but it is much heavier. And my design has pontoons so even if the hull gets a leak it won’t sink.
How much is HDPE? Is it a cheaper boat building material compared to fiberglass or steel? This is interesting stuff...I was thinking it would be cool to build small barges with the stuff, for either workboats or pleasure crafts.
A single 4x8 sheet of 1/4” HDPE cost me $75 USD. A 50ft length of 1/2” wall pipe cost $1000 USD. So for around $1600 or so you could build a. 16ft boat.
@@WoodLander-if you forget about the time it takes thats not a bad deal at all
@@WoodLander- What is the pipe diameter ? Thanks
The millings from the chainsaw cutting straight on the lawn?
wont kill the earth
do you know there's been 2000 + nukes exploded on, in, around earth
Saves mowing the grass once it's totally displaced. Shame the pipe doesn't come in a nice grass green colour tho! 😁😁😁
Let's talk price comparison
how will you connect the hdpe boards?
I have been fusing everything by hand with a heat gun and special tips and HDPE rods. It’s like tig welding but with plastic
Check out part 2
I build small sailing catamarans, of ply'wd, epoxy/glass,.... Might I ask the weight of the finished bare hull, please? VERY-canny work, though I'd bet you'd have built here "better", if a thinner-gauge pipe was used, no? Poly-pipe like that, here in SW FL, USA is absolutely indestructible!! (against direct-hurricane & wave-action, anyway? :-) Compare that I'm using 1/4" ply'wd, right,... for a 20'x9' near-shore mini-crusing vessel, and VERY-light. And, hopefully...nearly-indestructable ))) How's her draft, please? mine is 8". tanx, and buona fortuna!!
It is not done yet. And I will post the other videos as I continue. I estimate the total weight of the bare hull will be 300 lbs.
Hdpe won’t float on top of water.
Missing in Action
No part II in four months so far. Hope you weren't drowned by a breaking boat or arrested over stolen HDPE pipe? That stuff is FAR king expensive. Unless rejected for being dirty like that stuff was.
Nope. Part 2 just released. I got the pipe for free because is was set to be sent to the trash. I bought the sheet material. And so far I am still welding lot to do yet.
@@WoodLander- I caught it a few hours after watching the first edition. I'm lovin' this project Mr. When you said jet drive I knew you have the functionality sussed out. Stern drive might be fine for deep or salt water but jets allow it to go anyplace wet.
Releasing all that plastic particles into the environment is bad for all life.
that aint plywood..