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 »  Home  »  Boat Building  »  Building in Steel or Aluminum - Part 1
Building in Steel or Aluminum - Part 1
By Bruce Roberts | Published  05/17/2006 | Boat Building | Rating:
Building From Scratch - The Plans

To build a boat from scratch you need a set of suitable boat plans; hopefully your plans will include full-size patterns for the frames and stem. Below is a list of what our own design office supplies in this regard. With the advent of modern computer yacht design we have been able to offer the complete plans on CD. The benefit of receiving you plans and full-size patterns in this way is that you can have as many prints made of each sheet as you may need. For instance, if you are looking for quotes on either having the hull built or to purchase some piece of equipment or quotes for mast and sails; all these suppliers want to see the plans. You will find that having the ability to have the plans printed locally will offer many advantages during the building program. Also on the CD the designer can supply photos of similar boats under construction and other printed material that will assist you to better understand the plans and the boatbuilding process in hand. As most printed plans cover many large sheets of paper, it costs a considerable amount in postage, (usually about $/€50 or £35) to deliver from the designer to you. CDs can be mailed for a very modest cost.

 

   Using the boat plans shown below and a collection of appropriate materials you can build a boat from scratch. You make the frames from the patterns supplied and then you make patterns for each subsequent part as you continue to build the boat.

 

As mentioned earlier, your plans can arrive either printed on paper or as printing files on a CD. You should receive the latest updated version of your selected boat plan, which is only possible when you order your plans direct from the designer. You will receive many construction sheets, which include copious written notes as well as the detailed drawings necessary to build all parts of your boat.

   The following list is what we consider to be a complete set of plans and full-size patterns to enable you to build your boat with the minimum time spent in doubt as to how and what to do next!

        Sheet 1A (there may be several sheets covering various versions of the same design). These sheets cover the boat's general arrangement drawings, profile and plan views of the hull, the deck and superstructure, plus the deck plan. In the case of sailboats, the sail plan and measurements are usually included on these sheets.

        Sheet 1AA (there may be several sheets covering various versions of the same design). These sheets show the boat accommodation laid out and shown in plan and profile views. The several versions of the design are shown on separate sheets. Also included is a list for all the materials needed to build the hull deck and superstructure. In the case where the boat can be constructed of a variety of materials, these are all listed to allow you to cost out the boat in each.

        Sheet 2. The boat lines plan shows hull sections, profile including all water and buttock lines, and plan view including all water lines and buttock lines. All frame spacing, stern or transom detail, keel measurements, and rudder and skeg should all be included and all dimensions clearly shown.

        Sheet 3. This sheet will be a reduced drawing, representing what you can expect to see when you lay out the full-size boat hull patterns. We call this sheet the key to full-size patterns; it acts as a key when arranging the hull patterns and will enable you to readily understand just what the patterns contain. This sheet will help you resist the temptation of trying to lay out the patterns on your living room floor.

        Sheet 4. This sheet shows you how to manufacture and assemble the frames, plus form up the stem and other parts of the basic framework. This sheet also shows how to set up all these items on a strong back or a system of bedlogs, which forms the shape of your hull.

        Sheet 5. This sheet shows the installation of the stringers and deck shelf plus the installation of the plating in metal boats. In the case of radius-chine boats, additional information is supplied on installing these plates. Assuming you are building upside down, this sheet will show the turning-over process.

        Sheet 6. Now the boat is upright and this sheet covers the inside of the hull, and shows the installation of the floor webs, bulkheads, engine beds, and all interior stiffeners for your boat.

        Sheet 7. This sheet may show detail of the various items not covered in sheet 6. Often it takes two or more sheets to cover webs and bulkheads.

        Sheet 8. This is the engineering sheet that covers the engine installation, locating and building the fuel and water tanks, and making the rudder. Also included are details on making the stern and rudder tubes plus propeller shaft detail. Stanchions, swim platforms, and similar items may also be on this sheet.

        You may note that much of the above work can be completed before the deck and superstructure are in place. It is far easier to install the heavier items such as the engine before the "top" goes on. Individual builders will have a preference in this regard.

        Sheet 9. This sheet shows details the forming and installation of deck beams, side decks, foredeck, aft deck, cockpit construction and all deck framing detail of your boat design.

        Sheet 10. This sheet shows the patterning and making of the cabin sides, cabin front, etc. In the case of the cabin sides the measurements should be adequate to enable you to make up a plywood pattern and trial fit before cutting the actual cabin side plates.

        Sheet 11. This sheet covers such items as deck fittings, additional rudder construction, etc.

        A detail folio showing how to build some boat fittings and tools plus other valuable boat construction tips is included with all plans. When the plans are ordered on CD it is often possible to include numerous photos showing a sample boat under construction and examples of completed versions.

        Sheets A, B, C, D, E, F, G, and H are the full-size boat hull frame pattern sheets that are laid together like wallpaper. The full-size patterns contain details of all frame shapes, stem, deck and cabin top cambers, and the pattern for the expanded transom. Patterns are either paper or computer files (if you have plans supplied on CD), which can be printed out by your local print shop.

   This is a good time to mention that the professional who designed your boat may have spent many hours over some small detail believing that it will have an important bearing on the performance, appearance, or resale value of your boat. Respect his or her efforts, and please don’t make changes casually without consulting the designer.

 

Making and erecting the frames is one of the most exciting parts of building any boat. Having built a few boats myself, I know the thrill of seeing the frames erected for the first time, and of standing back and admiring the line of the hull. Of course, the addition of the chine bars (if present) and a few stringers gives a better idea of the shape of the hull, but the initial thrill of seeing the frames erected is still a most memorable occasion.

Material Lists

 

   You will get a better price if you order in bulk, so we recommend that you order all the basic hull materials in one combined package. Your building plans may include a material lists and, if so, it usually consists of the main items required for building the hull, deck, and superstructure. On some occasions, if you calculate the total weight of the metals, you may find that there appears to be too much material. Your list should include an allowance for off cuts and other wastage. The list may also include details of the temporary bracing required to set up the hull.

 

  Even if your plans include a materials list (including the lists included in our plans), go through the drawings carefully and “take off” the list for yourself. Don’t forget to allow for wastage; 15 to 20 percent is about right. Some of this wastage material will be used to make tools, including clamps and tags. The time required calculating the quantities will be a good investment, and it will prove invaluable in your better understanding of the plans. “One hour of study can save two hours of work” is an oft-quoted truism.

 

Most lists do not include the materials required for the interior joinery. In some cases, this list isn’t included because there may be several alternative accommodation plans. It’s better to compile a timber and plywood list after you’ve made a definite decision as to which interior you will finally select for your boat.
Article Series
This article is part 1 of a 2 part series. Other articles in this series are shown below:
  1. Building in Steel or Aluminum - Part 1
  2. Building in Steel or Aluminum - Part 2
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