Building an Aluminum Expedition Catamaran: A One-Year Timelapse

From Aluminum Stack to Ocean-Ready Catamaran

• 🛠️ The journey began with nine tons of CNC-cut 5083 marine-grade aluminum delivered to the shop in April 2024.
• 💡 Thousands of individual pieces, each etched with a number, were meticulously prepared to form the boat's structure.
• 🏗️ Sixteen frames, spaced one meter apart, were aligned with millimeter accuracy using lasers and a strong back.

Hull Fabrication and Welding

• 🌊 The first hull plates were welded onto the bottom of the bridge deck while the structure was still upside down, utilizing gravity for easier placement.
• ⚙️ A Sial English wheel was used to form each hull plate to a specific shape, a process that took about three weeks.
• 🔗 Longitudinal stiffeners were welded to the hull plates to add significant strength and rigidity.
• 🚢 After four months, the hull structure was nearly complete, with underwing girders welded on to provide strength and lifting points.

Flipping and Superstructure Construction

• 🚀 A major milestone was reached when cranes flipped the catamaran right side up, allowing for the welding of decks and superstructure.
• ⚡ The backbone of the electrical system, a large busbar equivalent to 500 mm² of solid copper, was installed to handle approximately 50 kilowatts of power.
• ☀️ The roof of the catamaran is designed to support five kilowatts of solar panels and collect rainwater for the tanks.
• 🌊 The slender, wave-piercing bows feature a strong collision bulkhead and a four-meter watertight compartment that will serve as a workshop and storage.

Interior Fit-Out and Systems

• 🔧 The interior fit-out began with the installation of non-structural bulkheads and flooring supports, using a lightweight, water-impervious plastic honeycomb material.
• 🚤 The propulsion system is a diesel-electric hybrid, utilizing a Yanmar 80 diesel engine and two 25-kilowatt electric motors.
• 💨 Ventilation is crucial, with a system designed to draw in cool, fresh air at the bottom of the engine room and extract hot air from the top.
• 🧰 Components like ladders, guest cabins, and galley cabinetry are fabricated with attention to detail, and all wall liners are attached with a fast-balance system for easy removal and maintenance.

Project Milestones and Support

• ✅ After one year and thousands of hours, the hull fabrication is finished, and water leak tests confirmed the integrity of the bulkheads and welds.
• 🤝 The build is a testament to the skills of Stradbroke Yachts, and the project is currently at the halfway point.
• 💖 Support for the ongoing journey and future videos can be provided through Patreon, with exclusive content and direct interaction with the builders.