aluminum sailboat build

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New build yachts

We are specialized in the building and finishing of aluminum custom built sailing yachts and have over 30 years experience.

Is your yacht in need of maintenance, repairs or a large refit? We’re happy to help you with it. We not only work on aluminium yachts but also on steel, polyester or even wooden yachts.

Designed by one of the world’s most legendary sailors as his private yacht. Brought to you by KM Yachtbuilders, the leading builder of aluminium expedition yachts up to 100ft.

We are KM Yachtbuilders

We build aluminium yachts. Starting out with three people and about as many yachts. A few decades later we are a team of 45 with more than 100 builds under our belt and our yachts are sailing the seven seas from pole to pole.

BOOT Düsseldorf

Get ready to experience the world’s largest indoor water sports show and explore the latest in boat technology, equipment and accessories. From sailboats to motor yachts, stand-up paddling […]

Choose your destination, comfortably go wherever you want to go.

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A custom built yacht is a journey in itself. Every customer comes with their own set of demands that depend on the purpose of the boat. Decades of experience, teamwork and a profound love of our craft help us to always come up with solutions for the most challenging demands.

Bestevaer yachts

Bestevaer s/y, bestevaer m/y, custom bestevaer 1/1, the world's finest explorer yachts., become part of the km family.

Our team is always ready to assist our yacht owners with advice and assistance in the event of contingencies.

Explore Bestevaer yachts

Designed by one of the world’s most legendary sailors as his private yacht. Brought to you by KM Yachtbuilders.

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Alubat [al.u.bat] noun | Aluminium Bateau | Aluminum Boat

Open House at Alubat

Join us at the Alubat boatyard in Les Sables d’Olonne, France for our Open House this coming May 31 to June 1 and get on board a new OVNI 370 and OVNI 430.

Amazing 43-ft Aluminum Sailboat

Full-time cruisers Roberta and Duca stopped by to visit us during the La Rochelle Boat Show for a tour of the NEW Ovni 430.

The ‘Small’ Huge Sailboat

Tour of the new Ovni 370 with Duca and Roberta on their YouTube channel Odd Life Crafting.

Aluminum Sailboat Misconceptions

“I have a friend, who knows a guy, who has a cousin, that bought an aluminum boat, and after a week in the marina the bottom fell out of her”.

Alubat Pricing

How Much Does a Well-Equipped Alubat Ovni Cost? Find out how we price the Ovni range of aluminum sailboats for the serious off-shore cruiser.

OVNI 490 Preview

The 490 shares some of the hallmarks of the Ovni range: shaft drive, full sailplan, centerboard, and spacious interior with a raised salon layout.

50 years of sailing excellence!

FIGARO nautisme | by François Tregouet

Half a century old and still thriving, Alubat, the Vendée-based shipyard, is not content with just being one of the world’s benchmarks in ocean cruising with its iconic Ovni yachts. Instead, with the enthusiasm of youth, it is preparing to launch three new monohulls over the next two years.

Link to read article [PDF]

STRENGTH ACROSS THE FULL RANGE OF ALUBAT Aluminum SAILBOATS

The new generation OVNI 370 with an inverted bow for improved performance and expanded the interior volume.

The new generation OVNI 430 with an inverted bow for improved performance and expanded the interior volume.

What sets the OVNI 490 apart are the protected pilot house and twin engines. 

The OVNI 450 stands out from the OVNI range and maintains a traditional cabin top styling.

Designing and building aluminum boats for blue water sailing. ​

The  Alubat shipyard  has been designing and building aluminum boats for blue water sailing since 1973. With more than 1,600 yachts built and with 50 years of expertise in metal work and carpentry, Alubat has unparalleled experience in the aluminum sailboat market.

Discover More

Aluminum is green

By having the ability to beach your boat, inspecting and servicing your yacht becomes less daunting than having to haul out.

beach your boat

Go places where other sailboats can't.

Centerboard advantages, navigate shallow water.

From the turquoise waters of the Bahamas to the Alaskan ice fields, a lifting keel gives you the peace of mind to navigate in shallow water. 

The centerboard doesn’t sacrifice performance or safety, in fact, it can enhance performance when it comes to downwind sailing. 

Another advantage of a centerboard is the expanded possibilities to find docking in marinas that would otherwise be too shallow for a fixed keel sailboat.

Without the limitations of fixed keel boats, your cruising opportunities can take you through the maze of Europe’s ancient canals and the historic North American waterways.

The centerboard can be lifted manually or by using a hydraulic system.

traverse canals

Owners sharing experiences from around the world.

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ALUBAT AMERICA

ALUBAT SHIPYARD

TRAVEL BOOKS

@ 2024 Alubat America. All rights reserved.

Aluminum Construction

All designs for aluminum construction are included here. For further study, we have books available in the Books, DVD's and Audio section of our store at your left. Read our free article on aluminum boat building,  HERE .

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Aluminum Boat Design Services &  NC Kits

Existing Kits, Custom & Semi-Custom

Modelling & modifications in all shapes & sizes.

Why buy or build someone's model X instead of the design you want,

with the look, feel and features that you want?

"The boat is a rock star!- Our "A" boat."

~ 32' pilot boat customer

"You guys are easy to work with, and your parts fit together real well."

~ professional boat builder

"Best looking boats around."

~ hobby builder

"I definitely wanted you to know how much I enjoyed working with you and your team.  I hope that we have more oppor-tunities to work together again at some point."

~ 31' landing craft customer

Background:

Response Marine has been designing welded aluminum boats since our first fire/rescue boat in 1989.  We are the primary supplier of designs and cutting files for a number of small boat builders and metal fabricators, and we also provide designs to individuals for one-off construction.   In addition to pure design work, we have spent most of these years embedded within boat building companies providing sales work, project management, shop supervision, and even rigging labor.  This background has yielded valuable, hands-on experience from the initial design concept thru construction and sea trials, as well as an appreciation for reliable performance and good structure that is sensibly assembled, aesthetically pleasing, and ruggedly built. 

Naturally, there have been many changes and improvements in both design software and construction practices in the past 30+ years.  Our early designs were developed in a combination of ProSurf and AutoCad and were set up for hand cutting all parts from provided dimensions.  For the past 20 years or so, we have been using MultiSurf for 3D modelling and plate development and then AutoCad for 3D views and 2D detailing.  The designs offered here are selected from those created since 2002, and they include files for the NC cutting of virtually all hull parts with the exception of extruded stiffeners for decks and superstructure.

Over the years we have learned darn near everything we know from our fellow builders, co-workers and customers.  Without their wealth of experience and challenges we would not be able to offer the range and quality of design services and kits that we do today.   

"YES! We're still very happy with our boat. We had a response to the north shore a couple weeks ago, in a snow storm, 6' seas, a few 8s and 10s also, and it handled extremely well. Even on the return trip with following seas. Breaks 2-plus inches of ice very nicely, too."

~ 30' fire rescue boat customer

Typical Design Kits:

Our Design packages include a single use of the NC cutting files, construction drawings, stock lists, parts lists and often a review of the weights and trim for the intended outfitting and application.  As a result of this latter process we may recommend some changes to the existing design.  While most kit sellers have a take-it-or-leave-it approach, we are more inclined to tweak our designs to suit both the mission and the preferences of  the owner. (For more on this, please see Custom Design .)

Each design was developed originally for a specific customer and application, but in many cases these specific-purpose designs are well suited for a range of applications whether they be commercial or recreational.  In many cases, minor and cost efficient changes may be incorporated to adapt a design from one application to another.  Furthermore, some of our designs may require modification before reselling in order to avoid infringement on any elements we consider proprietary to the original builder and important to their specific markets and sales efforts.  

We find that nearly all of our customers are interested in at least some changes to existing design kits- whether it be changing a console, revising gunnels, changing between welded flanges and formed flanges, or more major changes.    Accordingly, we do not have a formal price list, but will gladly quote once we have an understanding of your project.  You will find that each project is a collaborative effort among you, the builder/owner and the designers.  For multiple builds by the same customer we generally offer each subsequent hull license for a nominal 10 to 20% of the initial cost. 

Please see  Custom Design  for a description of easy changes to look and function, as well as a more complete description of our services.

"From the initial stages of designing you have made it easy for any changes we wanted to make, without major cost over-runs. Our 28’ Response Marine with twin 350 Yamahas was something that you don’t ordinarily do, but you made the modifications based on our request, basically redesigning the vessel to meet our specifications."

~ fire boat customer

"I LOVE our boats and parts wow."

" Every body here loves it.  The craftsmanship of  your boat is what the people are really PLEASED and bragging on."

~ rescue boat customer

"I wanted to thank you again for the design work you did for us on our club launch project.  We had it in full service for our opening weekend and the membership was beyond pleased with the results.  I have attached some pics of the finished build."

~ yacht club launch customer

• Aluminum Boat Plans

Aluminum Boat Designs and Plans Plans

Please browse our selection of stock aluminum boat designs (plans) below.

Please be aware that we have several designs available that are not shown on the webpage. Additionally, we may have variants of existing designs already in hand. For example, if we show a boat with an outboard (OB) motor, we may have an I/O option already on hand. Please feel free to contact us at (503) 543-7562 with any questions you may have.

Prices shown on this website are for plans and for a one time use of CAD cutting files.

My Cruiser Life Magazine

Aluminum Sailboat – The Ultimate Expedition Yacht?

Love them or hate them, aluminum sailboats are an excellent option for serious blue water cruising. They’re robust and sturdy and can come out of a scrap saying, “But you should see the other guy!”

Table of Contents

Advantages of aluminum sailboats, aluminum hull sailboat disadvantages, alubat ovni, garcia yachts, van de stadt, is an aluminum blue water sailboat right for you, faqs (frequently asked questions), why an aluminum sailboat.

In one particular niche of the sailboat industry, aluminum is all the rage. They certainly aren’t every man’s boat. Aluminum sailboats are reserved for high-end expedition-level long-distance cruising.

These boats are literally made to go anywhere and do anything. They’re practically indestructible, and they perform well. They can do things that make fiberglass boat owners fear for their gelcoat finish . Beach themselves on rocky shorelines? No problem. High latitude sailing while dodging icebergs? Sounds like part of a perfect cruise for an aluminum sailboat.

While browsing some of the aluminum sailboat manufacturers listed below, you’ll notice that many of these vessels look alike. They’re built for a similar purpose, after all. They are not charter boats going to the Caribbean—they are expedition yachts serving live aboard cruising couples.

These boats probably benefit from their limited market share. Their extra cost means that the makers don’t spend time marketing their boats to other buyers. The result is a sailing yacht that’s hyper-targeted to the task at hand—long-distance and long-term cruising.

Nearly all of these boats fall between 30 and 60 feet long, and nearly all of them are appointed for blue water cruising for a couple. In addition, more and more makers are branching into the multihull market, with several new aluminum catamarans coming out soon.

Once you start researching these boats and understanding the mission they’re designed for, their utility and robustness are apparent. For an owner who wants a worry-free vessel that can take on any challenge, it’s hard to beat an aluminum sailboat.

Here’s a list of just a few advantages of aluminum sailboats.

• Lighter than other sailboat materials
• Strong and difficult to damage, won’t crack
• Lifetime hull warranty possible
• Doesn’t need painting or top-coating
• Impervious to water—no blisters
• Doesn’t rust like steel
• More space down below
• Many are designed to dry out or sit on the bottom

Lightweight Material

Aluminum is used in many applications. Most aircraft are made of aluminum, so it is obviously lightweight and strong. It’s easy to machine into complex shapes and curves, and modern welding techniques mean it can be put together into a completely smooth surface.

Compared to other boat-building options, it is much stronger and thinner than fiberglass. It is lighter than wood, too. Compared to other metals, it is lighter than steel and does not rust.

The number one advantage of a metal boat is that it is strong. If your boat is made of metal, you don’t worry about scraping a dock or even bumping a rock. Gelcoat scratches and chips are a thing of the past. 

Metal boats are difficult to damage and won’t crack during an impact. In the worst case, it’s most likely that it will dent. Therefore, a hull breach is extremely unlikely. 

Compare this to the ubiquitous fiberglass boat, and the difference is stunning. Fiberglass is, by comparison, fragile. An impact with a sea buoy or a dock piling can easily cause cracking and severe damage to a GRP hull. These things are just in a day’s work for an aluminum hull.

Lifetime Hull Warranty Possible

The best aluminum sailboat makers can offer lifetime hull warranties. They put the time and effort into making their boats last a lifetime, and they will stand by that commitment.

No Painting

Love it or hate it, aluminum boats fare best without paint. Over time, the paint will bubble and chip away, so adding paint adds maintenance. As a result, most owners leave their aluminum hulls bare.

Impervious to Water

The fear of every fiberglass boat owner is the dreaded osmotic blister. These blisters form on the bottom of the boat and occur when water seeps into the fiberglass laminates. Of course, it’s not the end of the world, and they can be repaired and are preventable. But aluminum boats have no blisters—the metal is entirely impervious to water.

Doesn’t Rust

The other common option for vessels is steel. But unlike steel, these boats don’t rust. This is why they don’t have to be painted.

More Space Down Below

Compared to similar-sized fiberglass yachts, a boat will have more space down below. Since the hulls and bulkheads are thinner, they leave more space for storage and furniture. It might sound like a minor thing, but on a 30 or 35-foot sailing yacht, a few extra inches on each side of the cabin makes a huge difference.

Shallow Draft and Safe to Dry Out

Many of these designs are made to go absolutely anywhere. As such, shallow draft is a desirable feature—and one not often found on ocean-going blue water sailboats . Quite a few of these boats, particularly the French aluminum sailboats, have swing keel designs for getting in and out of skinny water.

For these boats, another great feature is the ability to dry out on their keel and remain upright. For areas with big tidal swings, this means access to harbors that dry on the outgoing tide. It also means easy access to haul-out facilities for repairs—just find a comfortable sandbar and do what you have to do.

Related: Best Trailerable Sailboats

If aluminum is so grand, why aren’t all sailboats made of it? Unfortunately, for as many pluses as these boats have, there are negatives as well. All boats are a compromise, so for all the benefits, you will have to give something up while you drive your boat around the boating world .

Here’s a list of a few disadvantages to owning an aluminum sailboat.

• More expensive to make and purchase
• Extreme care must be taken to avoid dissimilar metals penny in the bilge etc
• Subject to corrosion
• Harder to add deck fittings
• Repairs require specialized welding techniques expensive
• More difficult to apply anti-fouling paints
• Thinner hulls mean noisier rides and harder to heat and cool insulation is key
• Problems with weak welds
• Rare finds on the used market
• Custom one-off builds have the unpredictable build quality and resale value

More Expensive

Everything about an aluminum sailboat is more expensive. For the manufacturer, materials, labor, and construction time increase costs which they pay particular attention to. These are passed on to the buyer, so aluminum sailboats are nearly always more expensive than a comparable fiberglass yacht.

Dissimilar Metal Corrosion

Aluminum is more or less indestructible, with a few exceptions. What you get in protection from the elements and sturdiness at sea you pay for in routine maintenance and upgrades.

Aluminum quickly corrodes when it comes in contact with other metals. If you look at the aluminum mast of the typical sailboat, you’ll find corrosion around practically every stainless fastener. You must take extreme care to avoid dissimilar metals in a metal boat, where every attachment point and accessory presents the possibility of dissimilar metal corrosion.

Stories abound of people who have dropped pennies or batteries in the bilge only to find a hole corroded through the boat. To some extent, these problems are hyped up a little bit too much, but there is no denying that the danger is real.

Subject to Corrosion

While on the subject of corrosion, dissimilar metals are only one possible cause. Aluminum yachts must also be extremely careful of galvanic and electrolytic corrosion. So, in addition, you must take care that the boat’s electrical system does not introduce any stray DC currents. The same may be said of marinas and shore power connections, which can also introduce problems.

Harder to Add Deck Fittings

The risk of corrosion and damage to the aluminum hull and superstructure means that accessories or deck hardware are more difficult to add on. Generally speaking, drilling holes and bolting on new doodads is a straightforward task on a fiberglass boat. In the end, what matters is that it is sealed well enough not to allow water into the deck coring or the hull itself.

With these boats, things are a bit trickier. Owners are understandably more hesitant to go drilling holes in their expensive boats because holes are much harder to repair. Furthermore, unless all new hardware is made from aluminum, care must be taken to keep the two metals from touching. This might mean painting the metals or adding an extra layer of an insulator.

Difficult Repairs

Repairs to an aluminum boat require specialized welding techniques. It’s already boating, so the word specialized should be a warning—this isn’t going to be cheap. While you can pull into any port town in the world and find someone with fiberglass repair skills, a skilled aluminum welder might be a tougher ask. The good news is that it will need far fewer repairs throughout its lifetime.

Anti-Fouling Paint Problems

While regular boats can slap on any anti-foul that their local marine store or chandlery sells, aluminum boat owners need to be extra cautious. Like deck fittings and stray objects in the bilge can cause problems, so can the wrong paint. 

The active anti-fouling ingredient in most bottom paints is cuprous oxide. Copper reacts with aluminum and causes corrosion. So you cannot apply regular bottom paint directly to an aluminum hull. 

There are special paints that are safe for aluminum, however. It is generally believed that these formulas are at least somewhat less effective, which means you might have to reapply them more often or invest in bottom cleanings more often.

Thinner Hull Skin

For the same strength, aluminum is much thinner than other boat-building materials. It also conducts sound well. That means you will hear wave noise and hull slap more down below.

It also means that the boats will be harder to insulate against very hot or frigid weather. Newer boats make up for this with a perfect layer of insulation all around the hull, which should fix these problems. They’re still, like all boats, subject to condensation in the winter months.

Aluminum Boat Build Quality Problems

There aren’t many aluminum yachts on the market, which means that you are more likely to come across custom, one-off boats as a buyer. These may be works of art, but you’d have to research the shipyard that built it very carefully to determine if they have experience with aluminum yachts. These one-off boats often have unpredictable build qualities and a lower resale value.

For the most part, the production boats, even if they are custom or semi-custom models, have fewer problems. But issues with weak welds do pop up from time to time.

Finally, if you’re in the market for a used aluminum sailboat, you will likely need to search for a while. There aren’t many companies making them, and only a handful are built and sold each year. They are out there, but you’re going to have a very short list of options.

For example, a quick look at Yachtworld shows that for used sailboats between 30 and 50 feet long, there are currently listed the following.

• 5,665 Fiberglass or composite boats
• 87 Aluminum
• 9 Ferro cement

Best Aluminum Sailboat Makers

The original aluminum blue water sailboat was made famous by cruising legend Jimmy Cornell. Cornell did a five-year circumnavigation on Aventura III, an Ovni 43 .

Ovnis are centerboard yachts with shallow drafts. They have distinctive double hard chines on the hull and a go-anywhere look that feels as much at home anchored in a French Polynesian lagoon as it does tie to an iceberg in Patagonia.

Ovnis are built by Alubat, a French builder of several types of aluminum boats. They are currently marketing their new aluminum catamaran Ovnicat 48 , which will turn a few heads.

View this post on Instagram A post shared by Hobo Sailing Boat (@hobo_sailingboat)

Garcia makes expedition yachts between 45 and 60 feet. Their Exploration range of monohulls features raised salons and sleek lines that make them look like production fiberglass boats. Their boats feature centerboards and can be dried out thanks to their protected running gear and double rudders.

Garcia also makes a catamaran, the Explorcat 52 , and one-off designs for custom clients. Garcia yachts are built in France.

Kanter is a Canadian builder of top-quality aluminum yachts, both power, sail, and commercial vessels. Their pilothouse sailboats, available in sizes from 47 to 80, are as sleek as any fiberglass boat and built to go anywhere. Several designs come from the table of yacht designer Chuck Paine. 

View this post on Instagram A post shared by Grabau International (@grabauyachts)

Futuna, also built in France, makes expedition monohulls between 50 and 70 feet long. Their boats tend to look more like ocean racers, with a focus on performance.

Boreal yachts are unmistakable with their half-dome-shaped dodgers. The Boreal 44 has won numerous “sailboat of the year” awards. Boreal yachts have centerboards and can be dried out.

View this post on Instagram A post shared by Anne G Dørum (@feelgoodbyanne)

Meta has a storied past. They built Bernard Moitessier’s Joshua , the boat made famous in the book The Long Way . Today they build semi-custom and custom aluminum blue water and expedition boats in both power and sail.

Another popular French builder of aluminum yachts is Allures yachting. Their boats are between 40 and 50 feet in length and feature a similar centerboard design as the Ovni, Boreal, and some Garcias.

View this post on Instagram A post shared by Williams&SmithellsYachtBrokers (@williamssmithellsyachtbrokers)

Van de Stadt is not a boat brand but rather a famous Dutch yacht designer. Many of his plans were built in steel or aluminum, so it’s not uncommon to see Van de Stadts listed for sale.

Another famous designer of aluminum sailboats was German Kurt Reinke. Many of his boats are smaller and feature twin or bilge lifting keels.

If you’re in the market for an expedition yacht, looking at a circumnavigation, or are interested in sailing in high latitudes, an aluminum blue water sailboat is worth a look. Of course, like any yacht, they have their pluses and minus. But the peace of mind you’ll get from driving a nearly indestructible go-anywhere vessel is hard to beat.

How long do aluminum sailboats last?

If properly cared for, an aluminum sailboat has no particular lifespan. Several manufacturers offer lifetime warranties on their hulls. If the hull is well built and protected from corrosion, there is no reason that it couldn’t last forever.

What is the best material for a sailboat?

Most sailboats in the world today are built with fiberglass. It is inexpensive, easy to build with, and easy to repair. In addition, it is strong in its weight ratio and resistant to corrosion and deterioration. But unfortunately, it does not survive impacts well, and it is easily scratched or cracked by docks or rocks. Aluminum sailboats are considered much more robust. A well-built aluminum sailboat does not need to worry about getting scratched or damaged during regular use. Many sailors looking for expedition yachts consider aluminum the best material for these sailboats. Of course, each material has advantages and disadvantages.

What is the best hull material for a sailboat?

Most boats are built with fiberglass because it is generally considered the best overall value. When used to make the hull of a sailboat, it produces a rigid structure and is easy and less expensive to manufacture. However, it is protected by a delicate gelcoat layer, which will deteriorate over time. More expensive yachts favor metal construction for longevity. The best material for sailboats is aluminum, which can last forever if taken care of. It is much less likely to sustain damage like scratches or cracks than fiberglass.

Do aluminum boats last forever?

It is theoretically possible for an aluminum boat to last forever, as long as it is well cared for. Aluminum boats are sensitive to corrosion issues. But with regular maintenance, these boats can easily outlive their crews.

Matt has been boating around Florida for over 25 years in everything from small powerboats to large cruising catamarans. He currently lives aboard a 38-foot Cabo Rico sailboat with his wife Lucy and adventure dog Chelsea. Together, they cruise between winters in The Bahamas and summers in the Chesapeake Bay.

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What Aluminum Alloy Should I Use to Build a Boat, and Why?

All aluminum alloys are not created equal. 5052. T6-6061. What the heck do these numbers and letters mean? And more importantly, which one should I choose for my boat project ? Like most questions related to materials, the answer of course is “Well, it depends on your application.” To understand which is the appropriate aluminum to choose, it’s important to know a little bit about aluminum, its various alloys, and their properties.

Properties of Aluminum Alloy

Aluminum is an amazing material. Most can easily recognize one of its most distinctive qualities: weight. Compared to other metals, aluminum is incredibly light. It weighs about 1/3 as much as steel, yet has the strength to be used in structural applications, can be used in most fabrication processes, and can be cast, forged, formed, welded, machined, etc. Additionally, it’s particularly great for things that move, and combined with its exceptional resistance to corrosion, makes it an obvious choice for boat construction.

Aluminum Alloy Variations

The Aluminum Association of the United States has developed a naming system for the various alloys found commercially available, of which there are over 500 registered designations. Of the commercially available variations, four are most commonly used in the Marine Industry: 5052, 5083, 5086, and 6061. Typically, these alloys have a heat number of H3, which means they have been strain hardened and stabilized.

All 5000 alloys use magnesium as the principal alloying element. This makes the aluminum easier to weld, which is important for construction. It’s generally the “softest” of the four, and because of this it’s also considered the most workable. This aluminum alloy is not as susceptible to cracking during the forming process and is also the least expensive of the common marine alloys. 5052 is generally used for interior parts of the boat such as cabins, decks, and gunwales.

Aluminum alloy 5083 is commonly used by the US Navy. It’s stronger than 5052, yet it’s still formable and easily welded. This aluminum alloy is widely used in chemical and marine environments where corrosion resistance is crucial and can also withstand extremely cold temperatures without becoming brittle. But, all these great properties come at a higher cost than 5052, and although 5083 is stiffer than 5052, it’s also more prone to cracking. 5083’s corrosion resistance and toughness make it a great choice for hull bottoms and side sheets.

Considered the superior alloy for marine environments, 5086 has similar characteristics of 5083, but with added strength. This alloy is so close to its 5083 brother that the two are arguably interchangeable. In fact, 5086’s strength increases when it is cold worked. The main benefit of this aluminum alloy is its increased corrosion resistance properties, especially in salt water. It is the most popular choice for hull bottoms and side sheets.

This is a great general-purpose alloy. 6061 aluminum alloy can be used for structural components, as it has more strength than the other three listed above. It also has excellent finishing characteristics, so it can be used in areas that are highly visible to increase the aesthetics of the project. This added strength comes at a cost though, as this alloy is not as easily formable, is more prone to fracturing, and is only available in limited sizes. 6061 is commonly used for extrusions or exterior hull reinforcement, such as keel linings.

Naimor - Your Aluminum Boat Manufacturing Partner

At Naimor, we partner with clients to maximize simplify the boat building process. We work with naval architects, designers, builders, and fabricators to help them build the best boat possible. Our programmers are capable of unpacking complex 3D geometries and working with designers to produce repeatable, manufacturable components. We’re experts at sourcing materials and nesting parts to maximize sheet utilization and lower costs, and if we are able to find an alternate sheet size or material to save money, we pass those savings along to our customers. Check out our 7 Steps download below to learn more about how we ensure quality boat builds.

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7 Tips to Building an Aluminum Boat Successfully the First Time . 

Building your own boat is a huge accomplishment and something I will never forget. Boats bring people together, and can take you places a car just can’t go. For those of us who get satisfaction out of creating something by hand, there is nothing quite like building a boat. There are few straight lines, and the skill required is high, even for those that have years of experience. 

There are a number of companies online now, such as Metalbaotkits.com , who offer reasonably priced designs that you can download and build at home. If you’re a knowledgable welder, building your own boat is quite doable and very rewarding. A skilled welder ca lear the basics of aluminum boat building with some practice. However, there are a number of pitfalls that could cost you money and sink your dreams prematurely. So, before you go rushing in to build your first boat, consider the following: 

1) What kind of aluminum should I use? 

Boats are not just made with any old aluminum that you find at the metal store.The aluminum you want is marked by a few possible grades, either 5086 or 5083. It’s important you look at what your designer specifies and ensure that your metal supplier is aware of the grade you require.

In general, 5xxx series aluminum contains magnesium. This gives the metal a higher tensile strength without having to heat treat, and still allows for excellent workability and welding. It’s also important that you use an appropriate filler material. 5356 was specifically designed to work with 5000 series metal, and should be used when welding either 5086 or 5083 aluminum. For more information on types and grades, follow this link .   

2) Laser-cut vs waterjet vs router table?

After you purchase your design files, you will need to contract someone to cut the material for you. There are a number of options; the availability in your local area will likely dictate this choice for you. We used CJM Technologies , who specialize in CNC boat kits. They will fully cut your kit, and form all parts to spec. They even draw on the assembly lines for you. Here are some things to consider for the options:

Laser: the limiting factor in laser-cutting is not speed or quality, but the size of the table. Many companies won’t be able to nest your design. For example, we needed a 5’x20’ sheet of aluminum for our boat. Only a large router at CJM was able to tackle this. 

Waterjet: a good option and many shops have a machine large enough to cut your parts. The downside is edge prep. The waterjet leaves sand particles in the surface of the weld. You will need to grind all the edges before welding.   

Router: the best option for boat building due to large tables and no edge prep. The downside is that detailed cutting is limited to the size of the end mill being used. As most boat designs have been designed for a CNC router, this is not normally an issue unless there is an operator error. While a router is a great option, a bit of cleanup might be required. I found some interference issues in the joints of my jig, which required me to get in there with a little file and take out the cutter radius to make the jig fit correctly.    

3) What is a pulse mig welder and do I need one for boat building?  

Don’t think you’re going to get away with your trusty TIG welder to weld this boat. ⅛” aluminum transfers heat very quickly, even if you don’t burn through while welding. TIG WELDING WILL WARP AND DISTORT YOUR BOAT. This is bad. Let me say that again: DON’T TIG WELD EVERYTHING. Got it!? Ok good. 

So you’re going to spool-gun it then, right? Well, if you can afford a pulse mig machine, this is what you want. Professional boat builders will only use this kind of machine. However, they cost your first born child to buy, so maybe see if you can rent one for your build.

If a pulse mig is not an option, you need a spool gun for your welding machine. They are reasonably priced and most major manufacturers make them. You will need exceptional welding skills to use a standard spool gun though. Your boat kit will come with lots of crop/scrap aluminum. Practice your different welds. Avoid burning through. I have been welding for 17 years and completely burned through my first boat. I can’t stress this enough: take your time and PRACTICE.

Even better, hire a friend with boat-building skills. Have them go over the welding techniques with you. You will thank us later for this.  

4) Setting up the jig?  

The design files come with a jig. I chose to put mine on some custom-built sawhorses. You don’t need to do this; you can work off the floor. But it’s very important that the jig can’t move and is completely square. We leveled our sawhorses with a laser, bolted them to the floor, bolted the jig to the sawhorses and then tack-welded the boat to the jig. Some builders choose not to tack weld the jig. If it’s your first build I would highly recommend tacking the boat to the jig, as this will help you control distortion from welding.  

see figure 1  

For more on this step see our bog:

How to Build an Aluminum Boat – Part One:  Setting up the Jig

5) What is incremental backstep welding?

Boat builders use the ‘incremental backstep’ process. Read the instructions that have come with your kit carefully on this one and follow your designer’s standards. 

The primary idea behind back step welding is to eliminate distortion as much as possible. Starting from the center of the boat, work your way out in 6” increments, but welding towards the center. This is very important. Weld towards the middle of the boat, but sequencing your welds out for the middle. No idea what I’m talking about? See diagram.   

It’s important to work your way out in all directions, skipping every other weld in the process. Try to keep the heat from being concentrated in one area for too long. My designer stressed the importance of this process. DO NOT GO CRAZY WITH THE WELDING. Follow the incremental back step process.  

see figure 2

6) Forming the handrails?  

This one is easy. DON’T DO THIS YOURSELF. Unless you have experience or access to some expensive machines, you are going to regret it. I certainly did on my first build. Learn from me: I bought the $800 manual bender from the local store. After about eight hours of sweating profusely from manual tube bending, I will never do this again. Yes, you could heat the aluminum with a torch and make things easier. But if you don’t have these tools already, or access to them, just get a pro to do it. You’ll have enough on your plate already if this is your first build.   

7) Transom height?  

It’s important you decide what motor you’re going to mount on your boat before building the transom. Talk to the motor manufacturer and determine the best operating height of the motor. Not doing so could damage your motor or greatly reduce the performance. It’s a lot easier to measure in the beginning than to cut the transom down after you realize your motor is either too high, and sucking in air, or too low, and causing excessive drag.  

We hope these tips will help successfully build your first aluminum boat. Take these lessons from us, and get a specialist or a friend with the preferred experience to assist you. It will make the process that much smoother, and for those that feel boat-building just isn’t for them, no worries! We can do it for you! Learn more about our custom-built aluminum boats here.

Thanks for reading, 

Greg (& The Adventure Dog)

Owner, Adventure Marine

Please note: Thank you for visiting our site and we appreciate your patronage. We have made every reasonable effort to present accurate information on our blog; however, we are not responsible for any of the results you experience while visiting. This blog is made available by Adventure Marine for educational purposes only as well as to give you general information and a general understanding of boating, manufacturing, and parts, not to provide specific contruction/welding/legal advice. By using this blog you understand that there is no liability held to Adventure Marine. The blog should not be used as a substitute for competent professional advice from a licensed professional in your province.

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One of the first steps, and also one of the most important, in building your boat is setting up the jig. Boat hulls are constructed in a number of different ways, but for the purposes of this blog, I am going to focus on a design from MetalBoatKits.com. I have built two of designer Rick Wellins’ boats now. They have been rebranded as the Adventure 12 and the Adventure 16, as I have made modifications to both designs to suit my needs. They both use a similar jig and the setup process is identical for both boats.

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How Much Does It Cost to Build a Sailboat?

If you're on a tight budget, there are ways to build a sailboat affordably and still end up with a seaworthy boat. You can choose to start completely from scratch or consider using a self-build kit. If you want to hop on a sailboat project, let me help you break down the costs of building one.

The average price range for building a sailboat from scratch is between $10,000 and $20,000. A self-build kit for a 17' sailboat can be purchased for $2,500, while a sail-away Puur 17 kit can cost between $14,000 and $18,000. Meanwhile, building a 21ft gaff-rigged cutter can cost between $33,000 and $35,000.

If you're building dinghies, you can expect to spend anywhere from $1,500 to $10,000, depending on the size and materials used. Let's look at the estimated costs of building other types of sailboats and what factors can affect these costs.

• If you are on a tight budget, you can try starting to build a basic dinghy, which only costs around $1,500.
• If you're building a smaller boat, try to use less expensive materials, such as plywood or fiberglass, to keep costs down.
• You can save a significant amount of money on labor costs—around $10,000 if you do all the building yourself.
• A plan includes information on the materials needed for construction, as well as step-by-step instructions for assembling the boat.
• A catamaran with a more complex design or more advanced features costs around $50,000–$500,000 to build.

On this page:

Breakdown of costs in building a sailboat, average cost of building different types of sailboats, how to build a sailboat on a budget.

The average price range for building a sailboat from scratch is between $10,000 and $20,000 , but this can be much higher if you want to build an extremely high-quality craft or if you live in an area that is especially expensive.

Below is a table showing the estimated range of costs when building a sailboat:

Consider the materials you will use and the amount you need

Some common materials used in sailboat construction include fiberglass, wood, aluminum, and steel. The estimated cost of each material is as follows:

If you plan to build an aluminum sailboat, you might want to check out its pros and cons .

Factor in the costs of equipment

Building a sailboat requires a variety of specialized tools and equipment, such as saws, sanders, drills, and clamps. In addition to these basic tools, there are also more specialized pieces of equipment that may be necessary, such as a planer, a router, and a jointer. The table below shows how much each of these equipment costs:

Take into account the costs of labor

If you have the skills and experience to build the boat yourself, you can save a significant amount of money on labor costs. However, building a sailboat is a time-consuming process, and you should factor in the value of your time when calculating the overall cost of the project.

If you hire a professional boat builder, the cost of labor can be quite high, based on the complexity of the boat and the builder's experience and expertise. Although hiring a professional builder can be more expensive, it can ensure that the boat is built to high standards and is seaworthy.

Budget for purchasing a plan

If you are building a sailboat from plans, you will need to purchase the plans themselves. A plan refers to a set of detailed instructions and diagrams for building a specific sailboat design. It includes information on the materials needed for construction, as well as step-by-step instructions for assembling the boat.

Plans for a smaller, simpler sailboat may cost a few hundred dollars, while plans for a larger, more complex sailboat may cost several thousand dollars. The plan also includes the estimated timeline for completing the boat construction process. Building a sailing yacht can take at least 10 - 24 months to complete .

Carefully evaluate different sailboat plans before making a purchase to ensure that they are suitable for your needs and skill level. You may also want to consult with a professional boat builder or designer to help you choose the right plans and provide guidance during the construction process.

Account for miscellaneous expenses

There are a variety of other expenses which can add up quickly and should be factored into the overall cost of the project, such as the following:

• Permits: Depending on the location where the sailboat is being built, there may be permits required for construction.
• Insurance: Sailboats are valuable assets and require insurance coverage to protect against damage, loss, or theft. Insurance premiums can be a significant expense, especially for larger sailboats. Read this article to see the current costs of sailboat insurance.
• Transportation: If the sailboat is being constructed in a location that is far from the water, transportation costs may be incurred to move the boat to the water. This can include fees for a trailer, a truck, or a professional boat transport company.
• Miscellaneous Materials: There may be other materials required for the project that are not included in the initial cost estimate, such as hardware such as screws, bolts, and fittings, which may need to be purchased separately.

Sailboats come in various types, each designed with different features and purposes. The type of sailboat you choose will affect the cost of building it. Here are some common types of sailboats and their average costs:

The cost of building a dinghy

Dinghies are small sailboats that are typically used for racing or leisure sailing. They are usually less than 20 feet long and are designed to be sailed by one or two people.

For a basic dinghy, the cost can be as low as $1,500. This would typically involve using plywood or fiberglass for the hull, and basic rigging and hardware. However, for a more high-end dinghy, the cost can be as much as $10,000 or more. This would typically involve using high-quality materials such as carbon fiber or Kevlar for the hull, and more advanced rigging and hardware.

The cost of building a daysailer

Daysailers are slightly larger than dinghies and are designed for sailors who want to enjoy a day on the water without the expense and maintenance of a larger boat. Daysailers come in a variety of designs, from traditional wooden boats to modern fiberglass models. Some popular brands of daysailers include the J/Boat, the Laser, and the Sunfish.

These types of sailboats can accommodate up to six people and are usually between 20 and 30 feet long. A basic daysailer can be built for as little as $10,000, while a more luxurious model can cost upwards of $30,000. The most common materials used for building daysailers are wood, fiberglass, and aluminum.

The cost of building a cruiser

Cruisers are larger sailboats that are designed for long-distance sailing. The best-size cruiser usually ranges from 30 - 40 feet long.

Building a cruiser can cost between $30,000 and $100,000. Some cruisers may have additional amenities such as a kitchen, bathroom, and sleeping quarters, which can increase the overall cost.

The cost of building a racing sailboat

Racing sailboats are designed for speed and agility. They are usually between 20 and 30 feet long and are built with lightweight materials.

Building a racing sailboat can cost between $20,000 and $50,000, depending on the size and materials used. Since these sailboats are designed to be as lightweight as possible, it means that high-performance materials such as carbon fiber may be used, which can increase the overall cost.

The cost of building a catamaran

Catamarans are sailboats with two hulls. They are designed for stability and speed and are usually between 30 and 50 feet long, but the perfect size for sailing is around 37037 feet . Building a catamaran can cost between $50,000 and $500,000.

The larger the catamaran, the more expensive it will be to build. The materials used in the construction of the catamaran can also impact the cost, so if a catamaran is made of fiberglass, it will be less expensive than one made of carbon fiber. A catamaran with a more complex design or more advanced features will generally cost more to build.

The cost of building a trimaran

Trimarans are sailboats with three hulls, which are usually between 30 and 50 feet long. The cost of building a trimaran ranges between $50,000 and $500,000.

Since trimarans are generally larger and more complex than monohull boats, they require more materials and labor to build. Additionally, trimarans often require specialized equipment and expertise to construct, which can drive up the cost of the project.

Trimarans are also often built using high-quality materials like carbon fiber, Kevlar, and other advanced composites, which can be quite expensive. These materials are chosen for their strength, durability, and lightweight, which are all important factors for a high-performance sailing vessel.

Below are some tips to help you build a seaworthy sailboat without breaking the bank:

Consider a self-build kit : If you're handy with tools and have some building experience, you might want to consider a self-build sailboat kit. These kits come with everything you need to build a sailboat, including plans, materials, and hardware. Self-build kits can be a cost-effective way to build a sailboat, with prices ranging from $2,500 for a 17' sailboat kit to $14,000 to $18,000 for a Puur 17 kit, whichever you'd like to choose.

Choose your materials wisely : You don't want to skimp on quality, but you also don't want to overspend on expensive materials. With this, perhaps consider using plywood instead of solid wood for the hull, as it's more affordable and easier to work with. You can also look for deals on used materials, such as sails, rigging, and hardware, to save money.

Keep it simple : The more complex the design, the more expensive it will be to build. A simple design with a basic rig can be just as seaworthy as a more complex design, and it will be easier and cheaper to build.

Do it yourself : If you have the skills and experience, try doing as much of the work yourself as possible. This can include everything from building the hull to installing the rigging and hardware. Doing the work yourself can save you a lot of money on labor costs, and it can be a rewarding experience to build your own sailboat from scratch.

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