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Building an aluminum expeditionary catamaran requires extensive planning for plumbing and interior bulkhead construction. The crew installs various fittings for water and black water tanks, including fill lines, vents, and pump-out hoses.1:40 They encounter challenges with hose sizing, specifically finding that standard 38-millimeter fill hoses are oversized for typical marina infrastructure, leading them to adapt designs with smaller 19-millimeter fittings.2:14 To maintain watertight integrity, they weld mounting plates onto bulkheads for secure hose pass-throughs.4:28 For interior cabinetry, the team develops a method to create curved bulkheads by kerfing wood panels and filling the slots with structural epoxy.13:10 They construct a custom jig to hold these panels at a precise radius while the epoxy cures.15:14 This process replaces the need for multiple separate pieces, increasing structural strength and simplifying finishing work. The project involves constant iteration, including testing different epoxy types and adjusting bulkhead placement relative to the boat's centerline.22:07

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