'Applied Metal Boatbuilding Methods'
Sheetmetal Pattern Development

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'Metal Fabrication' is the creation of metal structures by cutting and bending sheet-metal, than assembling those formed components into a pre-determined product.

‘Applied Metal Boatbuilding Methods’ – ‘Sheetmetal Pattern Development’ picks up after the hull and deck of a boat is constructed. Devoid of all features or a 'Bare Hull'. It begins another phase of the build with the fabrication of integrals such as but not limited to: Coamings, Hatches, Window Ports, Companionways, and Tanks. Some builder may ever want to fabricate there own mast and booms.

Fabrication of these components by the builder is another major economic advantage of building in steel or aluminum. Components such as these can be fabricated for nickels and dimes on the dollar over purchased manufactured versions of the product.

Custom fabricated steel components are also more in keeping with the hulls construction material ensuing a harmonious steel design that is not attainable using components designed for another construction material.

Layout and fabrication of these type of components are determined by well established empirical formulas known as ‘Bend Allowance’ and ‘Bend Deduction’. These formulas are in universal use throughout the metal fabrication industry.

‘Applied Metal Boatbuilding Methods’ – ‘Sheetmetal Pattern Development’ is a Metal Fabricators course in ‘Precision Sheet Metal Layout’. Teaching the theory, principles and application of these well established Sheetmetal layout formulas to calculate the cut sizes, locations of bend lines and interior features demonstrated through the fabrication of marine components typical to steel and aluminum pleasure craft.

It is a complete guide to all persons in the metal fabrication industry be they Precision Metal Fabricators or ‘One Of’ Metal Boat Builders. ‘Applied Metal Boatbuilding Methods’ – ‘Sheetmetal Pattern Development’ is basic to rounding out your metalworking layout skills.

Part I - Fundamentals:  

   Bend Angles:                                      Page 10

   Bend Terminology:                             Page 12

   Bend Dimensions:                              Page 14

   Press Brake Tooling:                          Page 17

Part II - Preliminary Calculations:

    Inside Radius Calculations:               Page 21

    Bending Modes:                                 Page 22

    Tonnage Calculations:                       Page 28

    Round Punch Calculations:                Page 31

    Bump Forming:                                  Page 33

    Tool – Bend Conflicts:                        Page 34

Part III – Formulas:

   Formula Accuracies:                            Page 38

   Bend Allowance:                                  Page 39

   Bend Deduction:                                  Page 47

   Test Bending:                                      Page 52

   Dimension Conversion :                      Page 56

Part IV - Shop Drawings:

   Component Design and Layout:         Page  66

Part V – Deck Openings:


   Raised Coamings:                                Page 80

   Solid Hatch Cover:                               Page 83

   Skylight Hatch Cover:                          Page 89

   Production Hatches:                             Page 92

Part VI – Port-Lights:

   Introduction:                                        Page 102

  Fixed Coaming Port-Lights:                  Page 103

  Fixed Mitered Port-Light:                     Page 110

  Installing Production Ports                   Page 117  

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