Aluminum Catamaran Build: Insulation Prep and Application on SV Delos

Insulation Prep and Planning

• 🛠️ The team is in the crucial prep phase for insulation on the aluminum catamaran, with a tight deadline of seven days before spray foaming.
• 💡 Months of research and planning have gone into this make-or-break job, which involves insulating the entire hull.
• 📌 Key tasks include finishing all welding inside the boat, creating attachment points for future furniture, and running all conduits for AC and DC power.
• 🔌 All plumbing hoses also need to be run and terminated before insulation.

Foam Insulation Methods

• 🌊 For areas like the steering linkage where spray foam is difficult, 25mm closed-cell foam sheets are being used, chosen for their buoyancy, fire resistance, and insulation properties.
• 🎯 These foam sheets are custom-cut and fitted, with channels gouged out for moving parts like the steering shaft.
• 🏠 Similar methods are applied around other services like gray water drains or conduits that might require future access.

Surface Preparation and Coating

• ✨ Before spray foam, all aluminum surfaces must be cleaned thoroughly and dried completely.
• 🛡️ A coating called 'lic' is applied to protect the aluminum from corrosion, especially in areas that will be sealed off.
• 💧 The 'lic' spray is tested, showing its ability to repel water and prevent it from penetrating the metal.

Application and Challenges

• 💨 The team is using a spray foam compressor and gun for the main insulation, noting the strong smell and the need for respirators.
• 🚧 Dams are constructed around areas like door frames to control the spray foam application and create clean edges.
• 💧 A significant challenge is removing water from the bilge after cleaning, using bilge pumps and wet/dry vacuums.
• ⚙️ The process involves meticulous cleaning with Simple Green aircraft cleaner and water, followed by thorough drying.

Design and Material Choices

• 🎨 The team is visualizing interior design elements, using samples of veneer, foam-backed vinyl, galley colors, and countertop materials.
• 💡 A decision is made to use aged brass spotlights and reading lights for a warm aesthetic, moving away from traditional white or stainless steel options.
• 🚢 The overall goal is to create a comfortable and functional living space, with the insulation contributing to both.

Project Progress and Milestones

• ✅ Conduits are largely run, and supports for a custom desk have been welded.
• 🛠️ The team is pushing to complete cleaning, 'lic' spraying, and cutting out an escape patch hole before the spray foam specialists arrive.
• 🚀 Despite the tight schedule, there's confidence in meeting the insulation deadline.
• 📊 The main living spaces are insulated, with only a small area in the bilge remaining, and conduits are masked off in preparation for the spray foam application.