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Construction of a custom aluminum catamaran requires a non-linear, interdependent workflow where structural, mechanical, and interior systems must be dry-fitted simultaneously.0:53 To prepare the hull for insulation, the crew removes temporary 18mm plywood flooring to install permanent flooring and cut access hatches for the galley sink, bus bars, and steering assembly.2:22 Because spray foam insulation would interfere with moving parts, the team uses 25mm closed-cell polyethylene foam around the steering shaft, routing small channels to ensure clearance.14:01 Before applying foam, all aluminum surfaces are cleaned and coated with Nyalic to prevent corrosion caused by moisture trapped under insulation.23:22 The project also includes installing a deck-mounted flat winder for the traveler, which requires cutting a hole in the roof and welding a custom backing plate to accommodate the motor shaft and flange.25:55 The crew emphasizes that escape hatches are essential safety features for catamarans to allow egress in the event of a capsize.15:53

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