Aluminum For A SAILBOAT??? Why We’re GOING FOR IT! Part 2

We're building our DREAM BOAT....but why ALUMINUM? In this video, we explore why we chose this building material for our custom expeditionary catamaran, Delos 2.0. We delve into the key benefits of aluminum, such as its unmatched strength, durability, and corrosion resistance. But it’s not all smooth sailing— we also discuss the challenges and potential drawbacks of aluminum, plus solutions to combat these issues. We show you the reality of working with this material as we take you along a few pretty major projects like installing the engine bays, building and mounting the rudder tubes, and filling out the final frames all the way to the transom! And of course no discussion of aluminum would be complete without touching on how it stacks up compared to fiberglass. To put both materials to the test, we conduct a destruction test which was very ummmm *cough* educational....(and we might have had some fun running stuff over with a forklift and smashing away with a hammer). Whether you’re curious about boat building, considering materials for your own project, or just love a good showdown, this video has something for you!

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[DrBrian]

Hi Brian, I am a professional engineer with a PhD in engineering and I built aluminum boats in Canada for almost 20 years. Our company was called Yachtsmiths International and I believe you can still find some videos on youtube. Anyway, I wanted to bring something to your attention that you may not be aware of concerning aluminum boats. You need to inspect your hull plate welds very carefully. We had a 20 foot long weld seam in a 67 foot hull we built suddenly crack during construction despite the fact that our welders followed proper procedures using preheating where necessary and a backstep welding technique. This always bothered me as an engineer and as a sailor. Another strange occurrence that happened with aluminum was that a 53 foot boat we built suffered corrosion in their shaft tube 6 years after launching the boat. The piece in question was a 2 foot long piece of ¾ inch thick mechanical tubing, so it was supposed to be seamless but the pictures of the corrosion showed that it happened where the flow of the aluminum came together in the molding process. The boat was hauled and the repair was to tig weld the crack with proper heating. I am sure these two incidences were anomalies as none of the other aluminum boats we built ever had issues, but I just wanted to bring your attention to the fact that like any other material, aluminum can have strange things happen. Hope this helps...

[tomi]

In 2016, at 50 years old. I bought my first airplane. It was a project and we stripped it down to the bare airframe and completely rebuilt her over 2 1/2 years. Replaced some skin, new avionics, all new wiring, servos, landing gear, new engine, interior, paint... just rebuilt and restored EVERYTHING. Because of that adventure, I have learned way more about the construction, maintenance, troubleshooting and operation of the plane than my pilot friends who have owned aircraft for decades. Seeing you involve yourself in the build is heartwarming, and I personally know that this is a once in a lifetime experience for you. The knowledge you are gaining today can not be bought in any school. Wishing the very best for you and your beautiful family. I already know that Delos 2.0 is going to be nothing short of amazing, and you will be a part of her, knowing every piece inside and out.

[USBCABLEGUY]

Those offcuts of aluminium would make a great bottle opener

[davidnichols]

So nice to see Sierra loving Day Care and getting involved with the local children.

[Beer]

Reflecting on this project, Brian's words really hit home: "I didn't want to just throw a bunch of money at a boat builder..." That line stuck with me because it's exactly why this vessel—and this build—is so special. It's not just another off-the-shelf boat where nothing feels personal. This is different. You'll know every weld, every screw, every inch of it, and that will matter down the road.

What you guys have done here goes beyond just constructing a boat; it's about pouring in sweat, blood, and countless hours to create something with your own hands, something deeply personal. There's a unique pride in knowing that this isn't just another boat—it's a testament to your dedication, craftsmanship, and the shared journey of bringing it to life. 10/10 respect for the hard work and heart you've put into making this a reality.🌟 ⛵ 🌟

[joepaine]

Such a different approach to say, the La Vagabond's build. I see less ego and drive for sexy and speed and more focus on longevity and practicality. As a designer myself, love how this is going. Awesome

[dougmacdonald]

I started watching from the beginning...again. I'd love a video about "where are they now" - Babs, Frida, Max, and the many others we've gotten to know over the many years.

[jonathanwetherell]

The mark of a skilled craftsman is not that they don't make mistakes but how they get out of them.

[mellando]

So good to see Sierra having some time with other kids. Gonna be hard to leave that behind.
Watching the boat build is so fascinating.

[Moolahmann]

Man, Brian … I’m a journeyman carpenter wondered how you would pull this off and this is EPIC!! Stress free for us viewers and Exciting AF. I’m a patreon as soon as possible bro!!
Love you guys

[ernie]

Not to mention Brian, by being hands on you will know all the ins and outs of your boat. Which has got to be a real confident booster in sailing a catamaran. This so awesome to watch!!! Love you guys!!!❤

[dadthegrappler]

Brian, silicone sheets are sold in different sizes and thicknesses and are perfect for putting between stainless steel plates and the aluminum hull where necessary. They are also sooo much cleaner and easier to work with than caulk. Love your videos! Always genuine, informative, and definitely entertaining. Keep up the good work.

[Tyler-jbch]

11:46 Bottle opener for sure 👍 Congrats 🎉

[meadmaker]

To be honest, you could all of this in steel and lose a few of the problems that aluminum brings, while not really gaining any, except for a negligible weight difference. Having said that, watching these episodes reminds me of Steve Dashew and his legendary yacht designs, a number of which were done entirely in aluminum (Beowulf and the FPB series). Those aluminum boats really perform beautifully at sea and I can't wait to see Delos 2.0 riding the waves. She'll literally last forever if cared for properly. I like the diesel-electric setup as well. Really enjoying watching you take part in the build. It'll be massively satisfying once she's done.

[robertbeger]

30 something years ago I worked for a German expeditionary outfitter Globetrotter and helped to outfit a German man, Clarke Stede. He and his girlfriend sailed their aluminum sailboat through the Northwest Passage and circumnavigated both Americas. I remember talking to him about his boat and why he chose aluminum. I was impressed but have to admit a little lost at the time regarding the new (in my mind) material for boats. Besides all the collisions with ice in the Northwest Passage, somewhere in the South Atlantic they hit either a bouy broken free or a container. It punched a pretty good hole in their boat (I think it was double walled) and they kept on sailing and apparently it was an easy fix.

[macofish]

Kickin' ass and takin' names! You gotta let Dan and his team know how cool it is for them to be a part of this and show this process. This is so cool to watch as a single family home CAD guy. Cheers!

[bastisebi]

Been out of the Delos Game for maybe 2 years but now I am fully back in. New projects are always super exciting, especially building something unique like this aluminum boat

[Kaijet]

Bottle openers, key chains, sign or etch some, cnc snowflake tools, scrapers, the list goes on. Ultimately, I think maybe just the name Delos 2.0 etched or stamped on would be cool, a little piece of history. This is gonna be so incredible, so stoked to see the progress. Thank you.

[davidlam]

Kazaa is right about aluminum not being wasted and recycled. I saw somewhere that 95% of all the aluminum mined is still in use because almost all of it is recycled and it’s the most recycled material we have and that the amount of energy saved from recycling one aluminum can is surprisingly high.

[archstanton]

Brian you are getting one heck of a basic apprenticeship in metalworking. Fabricating with aluminum is a specialized art form, and doing curves with an English Wheel is a learned skill as I am sure you now know. If you ever wondered why cars with aluminum bodywork were more expensive now ya know. Compound curves are another lessen entirely.
Really enjoying this.