Learned the first important lessons

I really had some tough struggle welding the centerboard trunk & keel section.

I know that aluminum deforms when welded and I guessed that as aluminum is quite bendable I could correct this afterwards... Not so!

I learned that when this construction is welded it is enormously stiff and strong (which is positive as well of course). I also learned that complex constructions deform in unpredictable ways.
I had to consider more tack welds and a smart welding order. And I even may consider another design of the parts when I build this ship again.

Fortunately I could correct this trunk & keel within acceptable limits but that took several hours.
First I tried to bend the deformed parts resulting in more severe deformation in others parts, leading into too big gaps to weld and a kind of "modern art" in the end.

After a night sleep I decided to cut out the "modern art" and inserted a new piece. That worked out quite good. Welding the new piece deformed the side of the trunk again which I could prevent by cutting a few slits in the trunk to absorb the heath deformation and weld them afterwards water tight again 😇.

The section is not finished yet but hope that the most difficult part is done by now 🙏.

 

Cutting some more sheet and keel assembly

As I have to wait for the repair of my welding machine I had plenty of time to cut some more parts.
Didn't count the meters but it seems that the cutter is working better and better. Looks like it had to break-in but it also might have something to do with me getting some routine 😀.

In the animation above I am cutting the second bottom part.

In the pictures below there's a bit better view at the keel-trunk section taking shape...

 

Pretty shiny isn't it 😎.




My tiny pocket yard garage is filling up slowly. I developed a kind of workshop organization which looks like a "book" browsing through aluminum sheets and mdf templates.
This works well up untill I have to install the cradle. Luckily the garage door is still opening 😉.
           ⬇

First results & a bummer

Took a while since last post but a lot happened in the meantime: I drew the first pieces on the sheets with the templates, cut them and grind them to precise measurements. Which worked super! the sheet cutter did its job and the grinder slimmed the pieces down to the millimeter.

Welding something else than trial pieces was really different but I felt confident enough to build and shape the centerboard trunk and it actually surprised me that I made a firm piece of Pocketship.

First I had in mind to post some results when I finished the whole keel-and-trunk section but unfortunately my welding machine broke down after 1,5 week of perfect functioning. With a loud bang the machine stopped as well as the rest of the electricity in the house ;-). 

So cutting some parts in advance was the only option...

 

And of course I needed to "elongate" some pieces as well. In aluminum this is so simple: just make a straight and sturdy "butt weld" & grind it flat. After that it is immediately available for further process.

Hope to get my welding equipement back soon to be able to show you the complete keel&trunk section.

Aluminum arrived: Lets go!

This week the aluminum sheets came in. Opposite to most of the alu boat builders I decided to have two large sheets of 6 by 2 meters. These are of course much less manageable but with a bit of pre-cutting and "shunting" all the parts fitted in my mini alu-pocket yard.

Thanks to FNF metaal: Accurate company!

Thanks to HBM machines: Good advice, fine piece of tool,

 

 

Huge!!! Pocket Yard (in panorama shot of course...)

I already started with the centerboard trunk and keel section. And I can tell you there is so much to discover and so much to tell. I'll post the results within a few days...

New welding machine

This week my new welding machine came in. And today the argon bottle arrived so I could give it a try.

Yes! This little machine welds like a charm! I ordered a pedal (for current control) as well and this works absolutely great. The torch is not so bulky as @ welding classes and the machine can be set very precisely. I tried approximately 25 cm but this welder already earned my respect.

Assembling the torch was a bit of a hustle. The thread was a bit rough so it cost me a couple of  minutes and a bit of WD40 to get it done.

Now waiting for the aluminum (next week) and do some cuttings.

And even more templates

Some photo's of the latest templates. I now will be able to cut the hull including transom, bulkheads and floor frames. The keel templates were finished already...

Keel and centerboard box template

Bottom template

Side

Bulkheads and floor frames

How the bulkheads and frames look like (in wood)

New tools

Early this week I received my first set of extra tools. In this case a grinder with some specialized disks, a metal cutter and a welding helmet from HBM-machines (link at bottom of blog).

The metal cutter is a heavy type capable of cutting 4 mm steel. I guess 4 mm aluminum will do as well. The cutter had some good reviews (youtube) and the company where I bought it as well.

The Helmet is from the same company. There are automatic helmets available from around €200,- and from around €30,- As an amateur I found the second category more than reasonable.

I tested it yesterday at welding classes and it fits well and works nice.

The grinder spins ;-) Thats all I could test on the moment but I am confident that it will do its job.

Next purchase will be the Tig welding machine.