WHY BUILD IN
ALUMINUM

I used to be resistant to building with aluminum; I was strictly a steel guy. I've come to understand a bit more about the advantages of building with aluminum that few homebuilders consider (I used to be one of them).

When weighing the cost of construction, deciding on aluminum or steel, often a builder's first consideration is the huge difference in price between the two metals. Aluminum is three or more times the cost of steel, a real eye-opener, when undertaking such a lofty project as building a boat.

Often overlooked when considering building with steel are the related expenses and labor added to the cost. By the time you've ordered the steel and are well into the project, there's no turning back.

Think you're going to save the cost of sandblasting by doing it yourself? Think again, it grueling work - really grueling, I did it once - never ever again. Aluminum needs no sandblasting - Sandblasting cost alone could cover the higher cost of aluminum over steel.

Then there's the paint systems associated with steel - seems everything has to be painted with steel, inside and out - many gallons at approximately $150.00/gallon. A 35' boat will require at least 10 gallons - there's another $1500.00! Because steel is subject to rust, every nook, bend, beam and plate has to be protected with paint - forever.

The same size boat in aluminum requires only the cost of the "wash" (diluted with water) to etch (prepare) the surface, and about 3 gallons of paint ($450.00). The interior is always left unpainted - forever. While, the exterior is finished as required by the builder which could range from unpainted to being faired and painted to a fiberglass-like finish, the same as any metal boat. How expensive does that aluminum look now?

Because aluminum is light and easy to handle, it's a breeze to cut and form with common woodworking tools plus a Mig or Tig welder. It's less of a physical challenge.

Never welded aluminum before? You're not alone. Most folks are comfortable with welding steel and this is why they choose it. You will think differently once you try out today's easy to operate Mig and Tig welders. Find an opportunity on a small project, perhaps in the shop and you'll think differently about it.

Grinding aluminum welds are easier, faster, cleaner and safer. What flies off when grinding, is particle material not the heavy sparking associated with grinding steel welds.

• The lighter weight of aluminum allows a designer to direct additional weight to the ballast which greatly improves stability.
• When weight is focused in the ballast it creates more sail power.
• A lighter structure burns less fuel which translates into operational savings.

All metal boats (Steel and Aluminum) are affected by stray electrical currents from improper installation of 12-volt systems. Both steel and aluminum require cathode protection for dissimilar metals used underwater. Both require bonding and are equally at risk from stray current. Aluminum being lower in the galvanic series makes it higher at risk. However, when wired and protected properly, it is a non-issue for both aluminum and steel.

Not to minimize this, if building with any metal, I advise any builder to do some additional reading and research to ensure their boat will be properly protected. Here is a link to The American Boat & Yacht Council. They set the standards for safe boating.

Already discussed is the elimination of interior paint - off the list! Since there are no rust issues, the exterior needs only a paint freshening depending on the wear and tear, fade or the owner's choice. All other maintenance is the usual tasks associated with any boat.

The minimal maintenance, lighter weight and superior quality metal; make an aluminum boat more appealing to a buyer. Now, usually when you plan on building your own boat you don't consider ever selling it. Because you put your labor, sweat and cash into it, it becomes very personal. But unless you let it sit and rot in your retirement or decide to be buried in it, that boat will likely be sold one day. For this reason, a boat with a higher resale value is something to consider.

• More resistant to corrosion
• Less Maintenance
• Residual savings (no interior paint or labor to battle rust)
• Burns less Fuel
• Lighter weight, greater stability, sails better
• Higher Resale Value

If I knew then, what I know now, I would have built my 34' sloop in aluminum (years ago).

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