Sailing Umavideo
We Didn’t Expect to Weld on Our Fiberglass Boat | Step 469
11 January 2026 · 27 min · 96K views
What this video covers
Dan and Kika on the fiberglass sailboat Uma learn TIG welding from scratch as part of a major refit, with structural stainless and aluminum welds required for handrails, brackets, and other onboard hardware.▶ 2:26 Dan teaches himself using YouTube and ChatGPT — uploading weld photos with machine settings, tungsten tip condition, and gas flow specs, then iterating on AI feedback — before both he and Kika visit a professional metal boat builder called CAM in the Netherlands for hands-on instruction.▶ 2:55 At CAM, welders demonstrate aluminum and stainless TIG technique, covering heat management, travel speed, filler rod timing, post-gas coverage to prevent oxidization, mill scale removal, acetone cleaning, and how to read weld quality by color — straw color indicating correct gas coverage, mirror finish indicating a perfect stainless weld.▶ 12:22 Back aboard Uma, Dan fabricates aluminum brackets to hold electrical boxes in the cockpit locker, noting that aluminum is harder to weld but easier to cut and fabricate, while stainless is the reverse.▶ 20:33 A key limitation is their TIG welder's trigger-only heat control with no foot pedal, making heat taper on aluminum difficult.▶ 22:20 Dan also fills and polishes holes in Uma's stainless Cape Horn mast tube, with results invisible to the eye.▶ 19:22 Consistent short weld spurts with full post-gas cycles produce cleaner results than long continuous passes.▶ 16:14
More from Sailing Uma
From Sailing Uma — see the channel’s boat, crew, and every analysed video.