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Construction of a custom aluminum Orion 49 expedition sailboat involves integrating complex electrical and mechanical systems before applying hull insulation. Builders install plastic conduits through pre-cut holes in the aluminum frames to facilitate future wiring runs, ensuring cables remain accessible even after the hull receives approximately 6 centimeters of spray foam insulation.3:25 The design features a 48-volt Lewmar bow thruster positioned 185 millimeters below the waterline to prevent air intake.6:05 The electrical architecture includes a 28-kilowatt lithium battery bank for hybrid propulsion and a separate 24-volt system for general ship services.8:22 To prevent galvanic corrosion and odors, all bilge areas are painted white, and all through-hull fittings are welded directly into the aluminum structure rather than using traditional bronze or plastic components.11:48 Fresh water tanks are sandblasted and coated to maintain water quality, while fuel tanks remain bare aluminum.7:30 The layout includes dedicated drainage for air conditioning and shower systems, with wide decks and a reinforced bowsprit supporting a 35-kilogram anchor.13:54

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