How it's made

The Process

We build the hull on a jig and rely on careful distortion control — tacking every seam, then welding in short increments so the finished hull stays fair.

  1. Build the jig

    Assemble and tack-weld a square building jig to hold the hull true while it goes together.

    Tack-welded aluminum jig frame on the welding table

  2. Bottom plates

    Set the cut bottom plates into the jig and tack along the centerline so everything lines up.

    Tack-welded V-hull bottom plates on the welding table 3

  3. Bulkheads

    Install and weld in the bulkheads that divide and stiffen the hull.

    Construction Timelapse
    Construction Timelapse

  4. Gunnels & strakes

    Fit the aluminum rub-rail tubing and strakes before final welding to help control distortion.

    Construction Timelapse
    Construction Timelapse

  5. Transom

    Fit the transom and corner brackets at the stern.

    Construction Timelapse
    Construction Timelapse

  6. Back-step welding

    Weld the hull seams with incremental back-step technique — inside first, then back-ground and welded outside — to keep the hull fair and flat.

  7. Maker's mark & figurehead

    Design and manufacture the maker's mark, boat name, and figurehead — waterjet cut from aluminum and welded onto the boat.

    Waterjet-cut aluminum swan figurehead pieces laid out 2