Coming to a design website and asking help stealing plans for a boat currently in commercial production is generally considered bad form. Location: Eustis, FL I don't know of any free aluminum, welded jon boat plans available. Location: Washington 6 foot wide plus the flare to the sides generally comes out to a boat about 8 feet wide, which is the maximum trailerable width in most states. Location: New Orleans It depends on what type of ribs, and the attachment methods, and how much you are willing to spend. In a large commercial shop you would likely use a hydrolics press to stamp the shapes out of aluminium plate. For a one off build, either a Hand break machine if you have one available, or if not cut each piece, then weld it into place.
Location: Washington Where I come from braces are what dentists use to straighten your teeth.
Location: Seattle, Washington, USA Then there is the Brace and bit when you are drilling a hole by hand using a Wood Auger Bit.
Location: The Loft Good one Saildude, there is only one tool there and yet a brace is classed as two?
Location: Seattle, Washington, USA The Brace by it's self does not do much so you need the bit for the Brace to be much more than a wall hanging (OK you can also get countersinks, screwdrivers etc. Seattle is Mostly sunny today and Sunday - high about 66 degrees - - But if we wait until Tuesday or so the showers should be back to normal - Saildude View Public Profile View Saildude's Website View Saildude's Gallery Find all posts by Saildude Page 1 of 2 1 2 > « Am I crazy? When making potentially dangerous or financial decisions, always employ and consult appropriate professionals. See that your machine OCV (open curcuit voltage) is on par or higher than the requirement of the CO2 welding wire manufacture spec. Another trick welding aluminium is to remove all oxidation on the alu where you want to weld with sandpaper or file before welding it.
From experience I have found that it is easier to push the weld rather than pulling it as an arc weld.
Originally Posted by Wynand N Another trick welding aluminium is to remove all oxidation on the alu where you want to weld with sandpaper or file before welding it.
Location: Wasilla Alaska One of my Sign guy customers just bought the Lincoln your talking about getting. Location: Western Australia For what it is worth, I will throw in my opinion here as well. The 260 amp machine was big enough, but on a couple of the heavier welds I had it on maximum settings.
It sounds as though some of the people writing in this thread are learning alloy welding as they go.
If you are making MIG welds without this sort of testing you are risking wasting a large quantity of expensive alloy.


Location: Western Australia Yes, I designed it specifically to give good performance between 5 and 15 knots, as I have a place on a river area where there is a lot of concern about wake damage.
I have just towed the boat 500 miles north to a place called Shark Bay and it towed very well at 50 to 60 mph.
It is not perfect, as the broad quarters are inclined to lift in a following sea and some active steering input is required in long seas. Posesses a detachable stay which may work wonderful providing this sensor tearing hole to relocate horizontally in addition to vertically.
I would suggest thinking of either buying a boat from the manufacturer, likely for what it would cost to build, or looking for free plans of a similar type of boat. The first is that maximum width of a boat on a trailer is 8' so any wider than this means you have to have special permits. You could probably do most of the entire construction of a boat in just a few steps, though the set up cost would be million. A hand break is usually found in even small metal fabrication shops, so you might be able to either pay them to form the sheets, or rent access to the machine for a relatively small fee.
Lucie, FL New to welding Aluminum I was on earlier about MIG machines and you all warned me against buying a cheap machine. Because of the torch nozzle size, it is easier to see where you are welding and it produce a better looking weld. You can remove the closed-pore oxidation (old and foggy), and it would be replaced by an open-pore oxide layer (new and shiny).
I have built several steel and wooden vessels over the last 20 years but designed and built my first alloy (28 feet) boat two years ago. This was when welding 5mm plate to 10mm flat bar for the chine weld and 28mm round bar to 5mm plate on the stem. Helium mixtures are better for high penetration in thicker material and being lighter are also better for overhead welding.
It should be degreased and sanded clean of all old mill scale before assembly and it should also be wire brushed with a clean stainless steel wire brush immediately before welding. The spool gun might be OK, but if I had used one, I would have to build the boat differently, beacuse I don't think I could have got the bulkier unit into all the places I did. Lucie, FL Thanks for that; I am going to take a MIG course in the next semester.
It is not very efficient above 20 knots, as it causes a lot of turbulence as the water tries to follow the twist or warp in the hull. The mark 2 version that I am just finishing the desig for, will hopefully fix this problem. Unless you are used to doing this type of work, asking them to do it is probably a better option though. I bought the heaviest single phase (240 volt) machine available, which was a 260 amp machine with push feed on a 10 foot stinger.


The oxide on alloy melts at a much higher termperature than the metal and if you do not get rid of it it will sit in the weld in flakes and weaken the weld. Although this style is not my forte, I know what it takes in the design, developing, and construction aspects, to get a finished aluminum boat to look this nice. I have held off on this particular welder because I am still unsure of it's ability to handle the stock I generally use. I appreciate the offer of the spool guns but I had better hold off until I settle on something for a powerhead. The suppliers all looked very doubtfull that this was a big enough machine for what I wanted, but I did not want to go for a 440 volt three pahse machine, as this would limit its resale value. Because MIG is a semi-automatic process, machine settings and weld procedures are critical. With new plate material you can get away with just the wire brush but with weathered plate and all extrusions you have to sand or grind the mill scale off. Top speed empty has been around 15 knots and she cruises very comfortably in any sea conditions at 13 to 14 knots at about 10 to 12 litres per hour consumption. Most boats in Western Australia are designed to go 40 miles offshore and come back the same day. Now, what will hurt your weld is oil, dirt, the white residue that is left during oxidation, etc.
If you make a bad weld in alloy, you will not know until it fails, which could be catastrophic. Though my goals are much more modest and my welding will be mainly in fabrication on trailers and other gear. It is of course possible to weld three plates together to get a 12' wide plate, but this is again additional cost and complexity.
If I were commercial I wound not hesitate but as a hobbyist I think my wife might think about murder. In a MIG welding course, you are taught what causes a wedl to be rejected for visual faults and whwn you are making welds that pass visual inspection you are taught how to cut the weld test piece up and acid etch it to see just how good it is inside. Just a note that the Lincoln 175 turns out to be a lower end model built for the mass market and the price jumped to $617 so I bought a new Hobart Handler 180 from Airgas.
If this worlks, you note down all the machine settings in a procedure and use then settings next time you make this kind of weld.



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