Aluminum Boat Building

Aluminum is one of the best materials for constructing small boats.  It is not only light, but strong – it takes over 45,000 psi to tear it apart.  That’s a pretty durable material that can take a beating out there on choppy water.  Add to that the fact that aluminum is resistant to corrosion, and you are looking at a great material for your boat.

Many home boat builders enjoy building aluminum boats, because aluminum can be cut with basic carpentry tools with ease.

What are the other advantages of aluminum as a material for building boats?

• It does not need to be painted – paint can be very expensive, so this represents a big cost savings;
• Simple to weld;
• With basic care, aluminum boats can last a lifetime;
• Light weight, durable, and simple to maintain;
• Easy to transport because they are so light;

Before you decide to use aluminum as a boat building material, you should already have basic welding knowledge, including weld types and sequences.  If you do not know how to weld, it is fairly easy to get the basic skills needed, there are many schools available that offer courses, part time or full time, depending on how much time you have to dedicate to learning the skills you need.  If you want your boat to be aesthetically pleasing, you don’t want to have sloppy welds everywhere.  Practicing on less critical projects will probably get you up to speed in no time.  Of course, if you have absolutely no interest in welding, aluminum boat building is not for you.

There are a number of things required to build aluminum boats.  Not only do you need to buy the sheets of aluminum, but you need to be able to bend them to the shape required.  Factory boat builders use “jigs” to help form the hull and hold the pieces together when they are building aluminum boats.  If you are building your aluminum boat from scratch at home, the internal framework of the boat can act as your guide.

Buying Alloy/Aluminum

Stock plans for aluminum boats generally include the specifications required, such as size, type and alloy for framing.  If you cannot obtain specific materials, sometimes those plans allow for certain substitutions.  The most common marine alloy aluminum choices for welded hulls include:

• 5052-H32
• 5052-H34
• 5083-H321
• 5086-H32
• 5086-H112
• 5086-H116
• 6061
• 6063

The corrosion resistance for the 5000 series alloys is best in each case.  Each type of alloy listed here has specific tensile strength and varies in cost.  Your aluminum supplier can provide you with specific details about what can be substituted on a case by case basis.

It is also possible to purchase pre-cut metal to build your aluminum boat, but you have to be very specific, as well as accurate.  If one piece is not cut correctly, it could be a costly waste.

This is why obtaining plans and raw materials for aluminum boats is a cost effective way to build your own boat.  You can find the best low cost alternatives and make any changes you see fit to customize your vessel.