Building an Aluminum Sailboat Pt 4 - How the Hull Plates are Shaped
Distant Shores TV
Join award-winning documentary filmmakers Paul and Sheryl Shard as they manage their first hybrid-powered aluminum flagship, Distant Shores IV, in Bermuda in 2026.
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We’re Sheryl and Paul Shard, presenters of the Distant Shores sailing adventure TV series and Distant Shores YouTube channel. We’ve been cruising internationally since 1989 documenting the sailing lifestyle to inspire and inform anyone dreaming of sailing to distant shores. We invite you to follow our adventures as we build our next boat, a custom aluminum Enksail Orion 49.
This time on Distant Shores we get our first look at the boat welded together… We also dive deep into how flat aluminum plates are shaped into the smooth curved pieces needed to make a fast and strong sailboat hull. Then we take the opportunity to climb right inside our new boat and learn more about how the welds are made.
#boatbuilding #aluminumsailboat #aluminiumsailboat #timelapse #welding
00:00 Show Introduction and episode summary
00:40 Curved pieces of the hull, 3 methods of creating curves in aluminum
01:48 English Wheel and how flat pieces of aluminum are given 3D shape
03:20 How to check that the desired curve has been achieved
04:46 Klaas Kuperus explains the English Wheel and demonstrates how to use it
08:18 Our visit to the factory to see the hull of our Enksail Orion 49 welded together
09:14 Viewing the inside of the hull
09:35 Explanation of how the hull welds are made
11:11 Trying out the cockpit
11:21 Next build slot available and what’s coming up in future videos
11:57 Meet us at the United States Sailboat Show, Annapolis MD October 13-17, 2022
12:21 END
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See you at the United States Sailboat Show, City Dock, Annapolis MD October 13-17, 2022
We look forward to meeting you in person at the boat show in Annapolis! Here’s where to find us for “Meet & Greet”…
Thursday October 13
10 AM to 12 noon – Tent M5/M6 L&L Pardey Publications
Friday October 14
10 AM to 12 noon – Tent M5/M6 L&L Pardey Publications
3:00 PM to 4:00 PM – Sailing Channel booth, Vacation Basin
Saturday October 15
10 AM to 12 noon – Tent M5/M6 L&L Pardey Publications
Sunday October 16
10 AM to 12 noon – Tent M5/M6 L&L Pardey Publications
3:00 PM to 4:00 PM – Sailing Channel booth, Vacation Basin
Monday October 17
10 AM to 12 noon – Tent M5/M6 L&L Pardey Publications
4:30 PM to 5:30 PM – Sailing Channel booth, Vacation Basin
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Special Thanks to:
Enksail Yachts – https://gebrvanenkhuizen.nl/?lang=en
Satellite Yacht Design – https://www.yacht-design.nl/
KB Alubouw – https://www.kbalubouw.nl
KB Alufrees – https://kbalufrees.nl
Members of the Distant Shores Cruising Club whose support make these videos possible – https://www.patreon.com/distantshorestv
Partners:
BRNKL Yacht Security & Monitoring: https://www.brnkl.io/
Brunton’s Propellers: https://www.bruntonspropellers.com/
Seldén Mast / Furlex: https://www.seldenmast.com/ Lewmar: https://www.lewmar.com/
Raymarine: https://www.raymarine.com/
Scanstrut: https://www.scanstrut.com/
Navionics Charts: https://www.navionics.com/
GN Espace Galley Systems: https://www.gn-espace.com
Highfield Classic Inflatable: https://www.highfieldboats.com
Oceanskies Yacht Registration: https://www.oceanskies.com/yachts/
Gebroeders van Enkhuizen Boatbuilders – https://gebrvanenkhuizen.nl/?lang=en
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About Paul and Sheryl Shard
The Shards are award-winning travel documentary television producers and videographers who have been sailing internationally since 1989 documenting their global adventures for television, social media, in books and sailing publications. They have sailed over 120,000 nm including 9 ocean crossings and are the producers and presenters of the Distant Shores sailing adventure TV series which is broadcast to 47 million households in 24 languages around the world. Through their TV programs, YouTube videos, articles/blogs and popular boat show cruising seminars, the Shards help anyone dreaming of setting sail to get out on the water and experience their own adventures safely and comfortably.
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Gifts for Sailors!
Own the Whole Distant Shores Collection! All 157 full half-hour ad-free episodes of the Distant Shores Sailing Adventure TV series are available as HD downloads and also on DVD through the Distant Shores website. Get the whole set which is perfect for binge-watching, curing the blues and also makes a great gift for the sailor in your life! Info and order here:
https://distantshores.ca/sailingdvds/
Downloadable versions: https://distantshores.ca/sailingdvds/
WEBSITE: https://DistantShores.ca
FACEBOOK: https://www.facebook.com/DistantShoresTV
INSTAGRAM: https://www.instagram.com/DistantShoresTV
PATREON: https://www.patreon.com/DistantShoresTV
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