2272 Aluminum Custom Design/Build

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2272 Aluminum Custom Design/Build

Postby MotoStar929rr » Sat Jan 25, 2014 10:14 pm

So Ive been at it for a while now...I wanted a boat big enough to be safe and effective for the moderate size lakes and MO river found in the Midwest. I designed this thing probably 10 different ways before I finally started construction. Just like my other rigs, this is all AutoCAD designed. I even designed a jig in AutoCAD to help the beginning stages of construction. Started with a wireframe 3d model and worked into a full 3D Solid model. Laid out all the jig patterns on ply wood, then began the jig assembly. After assembly I leveled and anchored the jig to the floor. finally ready to begin on the boat. I started this build last February and still don't have it done. Between overtime at work, side work and fabrication for people, and life in general it's been quite an adventure getting this far. My regular camera is MIA, so all I have right now is the pics I've taken from my phone.
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CAM00128 (1024x768).jpg
Jig design on computer with wireframe model
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Re: 2272 Aluminum Custom Design/Build

Postby MotoStar929rr » Sat Jan 25, 2014 10:49 pm

Few pictures of the jig construction and beginning of boat construction. Jig was cut from 3/4 ply wood. Then screwed together.
CAM00151 (1024x768).jpg
Jig construction
After assembly I leveled the bow and stern patterns with a laser level. Remaining intermediate patterns were set with a string line. After alignment and leveling everything was anchored to the floor with tapcons.
CAM00157 (1024x768).jpg
Jig leveled and anchored
Jig made it a dream to put together. I design everything down to the ten thousandth in CAD. Then hand development is to approximately 30 thousandths at the worst. Accuracy in design led to accuracy in layout, which makes assembly easy when you're fitting up and welding out. Kind of like the saying aim small, miss small...
Next I had to layout the pattern on the 23'x6' material. The hull is all .125 5083 aluminum.
CAM00153 (1024x768).jpg
23'x6' sheets ready for development and cutting.
In order to save time, and make exact duplicates, 2 sheets of material were aligned on top of each other and clamped.
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Re: 2272 Aluminum Custom Design/Build

Postby MotoStar929rr » Sat Jan 25, 2014 11:01 pm

Next I did the parallel line layout to develop the triangulated patterns and finally got into cutting some material.
CAM00162 (768x1024).jpg
one of the bottom patterns
After cutting the 4pcs of the main hull I started fitting up and tacking the hull together.
CAM00167 (1024x768).jpg
fitting/tacking hull
CAM00168 (1024x768).jpg
fitting tacking hull 2
CAM00169 (1024x768).jpg
tacked up side/bottom on one side
CAM00173 (1024x768).jpg
4pc hull tacked up back
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Re: 2272 Aluminum Custom Design/Build

Postby MotoStar929rr » Sat Jan 25, 2014 11:21 pm

CAM00170 (1024x768).jpg
4pc hull tacked front

Next I cut and tacked in 3/4" round stock at all 3 hull seams. This is to add strength and support. Most mfgrs use and extrusion. I tried to get some from a few mfgrs, but they weren't having it. So I improvised. The round stock will be full welded bow to stern on both sides at the keel seam on inside, and stitched bow to stern on both sides of the inside of chine seams. After interior is mostly framed I will flip it over and back gouge the seams into the round stock and full weld all 3 seams for a water tight finish. I then started locating and cutting the 6 longitudinal braces. They are all 2x2x.125 6061 sq tube. I am building similar to a mud boat in that there will be no transverse bracing in contact with the bottom of the hull. So they will all attach to the sides and the top of the longitudinal bracing.
CAM00276 (1024x768).jpg
Round bar tacked/ longitudinals in place
CAM00285 (1024x768).jpg
Long in placex2
CAM00290 (1024x768).jpg
long in place back
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Re: 2272 Aluminum Custom Design/Build

Postby MotoStar929rr » Sat Jan 25, 2014 11:50 pm

I still cant find the camera, so I'm missing a few progress pics between the last post and now. But,...The next few steps were, to figure out how I was going to brace the bow portion of the hull. I gave thought to rolling/twisting alum tube. But after a trial piece I saw that turning into a mangled mess, and a nightmare to weld. So I ordered some 1/4" flat bar and made my own aluminum T bar. I made 1 pattern for each of the 3 locations and cut 2 of each pattern. Each flat or horizontal of the T is 3" wide. The verticals are all 2.25". After fairing out where it looked like it would work best I started tacking everything up. Once tacked up and ready to burn, I moved to the transverse bracing. It also, is 2x2x.125 sq tube. I cut each piece about a .25" short and used 3x3 sq pcs as pads to land each brace on. This should help keep from denting easier or tearing holes should an object impact right where the transverse brace ties into the side of the boat. All the tie in pcs attaching longitudinals to transverse bracing are .25" aluminum coupons welded to side of transverse and top of longitudinal. Next I cut the side supports out of 1.5x1.5x.125 sq tube and began attaching at the proper angle. These are really only a temporary support as the gunnel cap rails, decks, boxes, console, etc...will end up being the final support.
CAM00328 (1024x768).jpg
T-Bar/transverse/side supports tacked
CAM00329 (1024x768).jpg
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Re: 2272 Aluminum Custom Design/Build

Postby Mark F. Cheney » Sat Jan 25, 2014 11:56 pm

Hello, I appreciate the view of the wooden forming frames and the clear explanation of how you are going to do the long seams with the round stock. I thought that was a great idea. It is fun to see some one doing something.

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Re: 2272 Aluminum Custom Design/Build

Postby MotoStar929rr » Sun Jan 26, 2014 12:21 am

After all the bracing is in it was time to try and throw down some molten metal and make this thing more permanent. The positive air hood from adlfo/3m speedglas makes it really nice when you're doing a lot of welding on aluminum. no worries about where you're at or what position, etc... It was finally time to fire the miller 350p up and let her eat! This is the first time I've ever actually gotten the fan on demand to come on with this machine. Needless to say I have got some serious time under the hood burning this thing out. As long as it all works out in the end I'll be stoked. After burnout, I started working on the transom and bracing. The transom is framed out all the way around with 2x4x.25 6061 aluminum rect. tube. I cut all the parts, tacked up and verified the assembly to the transom sheet pattern.
CAM00345 (1024x768).jpg
transom tube frame
Next I clamped down the tubing to the table, weld prepped each joint, and burned it out.
CAM00346 (1024x768).jpg
clamped and welded out
I couldn't help but carry the frame over and set inside the boat...
CAM00347 (1024x768).jpg
Tube frame set in the hull
Next I cut out the transom pattern and welded it out to the transom tube frame.
CAM00348 (1024x768).jpg
Finished transom minus plug, set in the hull
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Re: 2272 Aluminum Custom Design/Build

Postby MotoStar929rr » Sun Jan 26, 2014 12:49 am

Next on the to do list is flip the rig over. It was nice having a fork truck and a few hands... Still a little sketchy, but me and some buddies got 'er done. Back to work, I certainly don't plan on treating this rig like a baby. I'm hoping to be able to break some decent size ice with it. So I'm installing 1.5x1.5x.1875" alum angle in 5 location across the bottom of the boat. 4 angles will be welded directly under the 4 outer longitudunals. THese will all be stitched. The 5th angle will run bow to stern on the centerline of the keel seam. This angle will be seal welded. The tacks seen on the heel of the angles are from tacking a piece of tube as a point of leverage to manipulate the angle straight and flat to the bottom of the hull...
CAM00190 (1024x768).jpg
angles welded to bottom1
CAM00189 (1024x768).jpg
angles welded to bottom2
Hoping that the little bit of distortion I have to live with will be far outweighed by the strength of the hull. I wont be setting any land speed records with this rig anyway, right?
Attachments
CAM00188 (1024x768).jpg
Some decent welds from the 350P
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Re: 2272 Aluminum Custom Design/Build

Postby MotoStar929rr » Sun Jan 26, 2014 1:09 am

Once done with the angle weld out it was time to get the trailer ready. Wish I had the camera for some pics of this process. I got a steal on a nice trailer. But I had to cut off the non adjustable bunk supports and remake new ones to match the boat. I also had to install longer bunks as the previous boat was a lund deep v. Turned out nice after all was said and done. After getting trailer ready for the boat, the boat we flipped her back over and set her on her new ride. At this point I only have the transom tacked in place. Now I'm ready to burn it out and install the plug tube as well.
CAM00194 (1024x768).jpg
transom welded out
After transom weld out is when I was most nervous out of the whole build so far. Time to leak test. I have some great penetrant dye and developer but, tbh, the stuff gets EVERYWHERE, and is a mess to clean up. SO, instead I installed the plug, put the trailer frame on several sets of jack stands and used the fork lift too, then filled her up with about 800 gallons of water.
CAM00195 (1024x768).jpg
beginning of leak check
CAM00197 (1024x768).jpg
Still filling her up!
I can honestly say I was a SOOOO happy that I didn't have a single leak in the whole boat!!! So stoked!!!
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Re: 2272 Aluminum Custom Design/Build

Postby MotoStar929rr » Sun Jan 26, 2014 1:19 am

Now that I'm good to go on the water tight seams, It's time for some intermediate floor bracing. The bracing is all out of 2x2x.125 sq tube as well. I'll have more pics of the floor bracing soon. After finishing floor bracing I have started on framing out the back deck and cutting some transom bracing. I'm only lacking a few vertical supports and a few small pieces for pedestal seat supports as of now. Shouldn't be long and I'll have back and front deck finished. Once there I'll finally be closing in on finishing this monster project. Looking forward to finally see it all come together.
CAM00440 (1024x768).jpg
front
CAM00441 (1024x768).jpg
back
CAM00438 (1024x768).jpg
back deck framing
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Re: 2272 Aluminum Custom Design/Build

Postby MotoStar929rr » Sun Jan 26, 2014 2:30 am

Mark F. Cheney wrote:Hello, I appreciate the view of the wooden forming frames and the clear explanation of how you are going to do the long seams with the round stock. I thought that was a great idea. It is fun to see some one doing something.

Mark f. Cheney

Thanks Mark. I like seeing everyone's creativity and craftsmanship. I take pride in my work and love seeing my builds come together.
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Re: 2272 Aluminum Custom Design/Build

Postby crohrer » Sun Jan 26, 2014 4:07 pm

thanks for the picture please keep them coming
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Re: 2272 Aluminum Custom Design/Build

Postby grizz18 » Sun Jan 26, 2014 4:16 pm

This is awesome. Can't wait to see the continued process and end result.
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Re: 2272 Aluminum Custom Design/Build

Postby 2500hdon37s » Sun Jan 26, 2014 5:55 pm

THIS. IS. AWESOME. You sir have some talent and patience! boat looks great so far!
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Re: 2272 Aluminum Custom Design/Build

Postby T Man » Sun Jan 26, 2014 9:53 pm

Thank you for sharing. This is a kickass build.
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Re: 2272 Aluminum Custom Design/Build

Postby QuackerSmacker498 » Mon Jan 27, 2014 12:26 pm

That thing is awesome!!! Extremely jealous of your project and work, hats off to you fellow hunter.

I don't know what type of motor and speeds you will be getting. One thing you may want too add near the bottom of the boat is a two inch splash guard. Its super common on aluminum bass boats. I have them and they help keep some of the water out of the boat in turns and in choppy water. Just a thought for you to consider. CHEERS ! :thumbsup:
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Re: 2272 Aluminum Custom Design/Build

Postby MotoStar929rr » Mon Jan 27, 2014 1:36 pm

2500hdon37s wrote:THIS. IS. AWESOME. You sir have some talent and patience! boat looks great so far!

Thanks guys. I've been dreaming of building a rig this size for a long time. Should be a safe, reliable rig once I get her finished up. I'm itching to see the dang thing float and run!
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Re: 2272 Aluminum Custom Design/Build

Postby MotoStar929rr » Mon Jan 27, 2014 1:56 pm

QuackerSmacker498 wrote:That thing is awesome!!! Extremely jealous of your project and work, hats off to you fellow hunter.

I don't know what type of motor and speeds you will be getting. One thing you may want too add near the bottom of the boat is a two inch splash guard. Its super common on aluminum bass boats. I have them and they help keep some of the water out of the boat in turns and in choppy water. Just a thought for you to consider. CHEERS ! :thumbsup:


I'm not sure what I'll end up pushing this thing with. It's a 25" transom and I got a steal on a Honda Bf150 I'm planning to bolt up to her. Im really hoping for 50+mph on calm water...and high 50s with current on the river...Not sure I'll hit that with the 150 without a terrible hole shot. If I'm not pleased with speed I'll be looking for a 200...I grew up racing Mx so I'm all about being faster than the next guy...if I have to... :yes:... Or maybe just because I can. Haha. I'm planning to add side stiffeners on the exterior that should help keep a fairly dry ride. I'm also planning to install floatation pods too. Feel free to suggest ideas. Always like hearing what works and other guys like/hate about their rigs. Thanks fellas!
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Re: 2272 Aluminum Custom Design/Build

Postby Tanner01 » Mon Feb 03, 2014 5:20 pm

That's a cool looking build. I am really impressed with how you design everything in Autocad. I wish my skills were better in that department.
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Re: 2272 Aluminum Custom Design/Build

Postby SouthernYank » Sun Apr 13, 2014 6:08 am

Build looks great, what progress has been made since the last pictures you posted? I wish I had the skill to build something close to that man. :bow:
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Re: 2272 Aluminum Custom Design/Build

Postby WoodyWhiffingMG » Fri Jun 27, 2014 6:00 am

Any progress?
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Re: 2272 Aluminum Custom Design/Build

Postby MotoStar929rr » Fri Jun 27, 2014 6:42 am

I wish I could tell you guys I got it done it's running like a champ...but I honestly haven't had time to work on it. I'm in the process of opening my own Mechanical and Fabrication shop, and ive been taking all the work that comes my way. That has left little time tinker with personal builds and projects. I'm really hoping to find enough time to get something rolling sooner than later. Just not enough hours in the day...soon I hope, soon. I'm hopeful that as I establish a client base as I am now, that I'll be able find a better balance of work and play...hard to do, especially with a wife and kids too...we'll see!
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Re: 2272 Aluminum Custom Design/Build

Postby WoodyWhiffingMG » Fri Jun 27, 2014 7:03 am

MotoStar929rr wrote:I wish I could tell you guys I got it done it's running like a champ...but I honestly haven't had time to work on it. I'm in the process of opening my own Mechanical and Fabrication shop, and ive been taking all the work that comes my way. That has left little time tinker with personal builds and projects. I'm really hoping to find enough time to get something rolling sooner than later. Just not enough hours in the day...soon I hope, soon. I'm hopeful that as I establish a client base as I am now, that I'll be able find a better balance of work and play...hard to do, especially with a wife and kids too...we'll see!


Opening your own business is just as cool as building your own boat, in my book! Good luck!
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Re: 2272 Aluminum Custom Design/Build

Postby grnhd » Mon Jul 07, 2014 9:32 pm

That is an awesome boat. Please post more pics when you can, I really enjoyed them.
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Re: 2272 Aluminum Custom Design/Build

Postby Tanner01 » Wed Jul 16, 2014 5:06 am

Have you made any foward progress on this boat?
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