The process of building the first Ovni 490 hull is extremely exciting for us. From flat aluminum sheets, the hull begins to take shape along the transversal aluminum frame. At the same time the hull is being built, both the deck and the cockpit begin to take shape to create Alubat’s 100% aluminum sailboat.
For more on the build process, link here to watch our factory tour with Luc as he explains the steps of building at Alubat.
The aluminum sheets are delivered cut and engraved by a subcontractor. The high quality aluminum is enriched with manganese for better capacity with sea water.
A jig is used to create the hull structure.
The steel structure is used to apply all the framing.
The grade of aluminum used for the steel structure is in the 60-range, which is higher than what is used on the sheets.
The framing ensures that the structure maintains its geometry
Watertight bulkheads are welded in the forepeak.
The aluminum frames are spot welded onto the frame to maintain their geometry.
The metal sheets are first spot welded onto the framing.
Alubat uses flat sheets to create the chine on it's vessels
Flat sheets are spot welded onto the frame
Once all the sheets are in position, the whole hull is welded together
The sheets are welded both on the inside and outside.
The Ovni range uses semi-thick plates that provide more resistance to impact.
The thickness of the aluminum sheets varies - with the thickest at the bottom, and slightly thinner on the side panels
The hull is ready to be lifted off the jig and moved to another part of the shipyard.
The Ovni 490 is built to accommodate twin engines.
Some of the structure can't be completed with the framing - the hull is removed from the jig to another part of the factory.
The framing is transversal to the hull, and not longitudinal.
After grinding to create a smooth structure.
The welding on the structure is not continuous. Welding changes the structural characteristics of the aluminum.
After grinding to create a smooth structure.
After grinding to create a smooth structure.
Similar to the hull construction, a steel jig is used to clamp the aluminum structure to the frame.
The aluminum frames are first spot welded to keep them in place and ensure proper framing.
Once the structure is in place, the aluminum sheets are welded onto the deck.
The cockpit is welded without the use of a steel structure. Instead, folded aluminum sheets are used to build the cockpit.
