As some of you may or may not know my wife and I are working through the process of building a boat. We are very early in the process. Nothing is actually built yet. We have a design that is almost perfect for our needs. We have had discussions with the designer about what it will cost in design fees to make it perfect. and then what it will cost extra to get all the hull plates rendered into CNC files to be cut out on a giant plasma cutter.
Now, in theory, I am trained in boat design and building. In fact I have designed and built boats. However, they have all been under twenty feet and made of wood. Plywood mostly. In fact I am a pretty good small plywood boat designer and builder. The problem here is: I know jack about designing and building steel boats. I know slightly more than jack about putting interiors in steel boats. I have fallen deeply in love with the concept of a well designed and constructed Steel yacht.
So I have gone to a designer who:
Has four decades or so of building boats
Steel ones
tugs, small island freighters, and private yachts that resemble same.
that has lived a board a boat of some sort for most of those four decades
makes a habit of designing interiors that meant to be lived in not just visited on the weekend
has some experience in the type of construction I wish to do
has a good relationship with the companies who will do the thingd I want done.
has a stock plan that is within five or six hours of drafting time of the boat I want.
His name is
Jay Benford.
There is a wonderful website for a
boat that may be the first one built the way that I intend to. They detail it in pretty decent photos on the site. The actual constructor of the boat was
Custom Steel Boats They have some wonderful photos on their site and a pretty description of the process used. The gist of it is this. Somebody (like
this company) takes the plans and lofts (which means make fullsize patterns for the pieces of the boat) them into NC files for use by a company that specializes in cutting out bits of steel with computer controlled plasmacutters. the company who cuts them out would ideally cut the steel out of pieces that are pre sandblasted and preprimed with a weldable primer. This means that when you finish the boat you don't have to sandblast the entire boat, just the weld seams, saving both the labor and the problem of what to do with a hull with several hundred pounds of sand in the bilge. the cutting company then ships the whole lot to you (or your
builder) with appropriate tab A into Slot B markings for your assembly. Once it welded and the seams are blasted and re-primed, the bilge sump is coated with several coats of epoxy to keep the boat from rusting from the inside out(which, incidentally is the most common way steel yachts die). The entire rest of the interior is covered with a couple inches of sprayed in place foam(not altogether unlike the stuff you might us to seal that bad patch of siding behind the gutters where nobody can see( go ahead deny it but you and I both know it's there)). The foam does several things all of them good:
it also seals the steel and prevents it from rusting from the inside out,
it prevents most of the condensation that would normally occur in a metal boat(many people who have uninsulated metal boats refer to the interior as "the rainforest"),
it keeps the interior cool in the summer and warm in the winter( surely you must know someone that has licked a steel flagpole in the winter?)
The exterior of the boat then gets primed with an epoxy primer and painted above the waterline with a pretty two part polyurethane, and below the waterline with a paint nasty enough to kill barnacles and the like(I should probably note at this point that I make my living selling just this sort of stuff and I'm damn good at it). Now you have something that looks like a boat. Now you get to spend about twice as much time as you have spent so far fitting in an interior putting a rig on it, probably an engine too unless you are some kind of nutjob purist. So let's make it three times as much as you have put in so far. But right now it looks like a boat so go ahead and woohoo if you need to.
In the process of researching this whole process I felt I needed to learn how to weld. I kind of know now but just the sort of stuff you do on a farm on an antique arc welder that is powered by the engine of the very same tractor you are trying to weld. certainly not the sort of professional look I would be going for here. So
here are
a bunch of
links that I found to larn ya the theory and practice of bonding metals.