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The crew installs the propulsion system for an aluminum catamaran, focusing on the alignment and mounting of the stern tube, 35mm prop shaft, and Brunton’s EcoStar H6 propeller.5:52 The process requires precise shaft alignment to prevent vibration and excessive wear, utilizing feeler gauges to measure clearance between the transmission flange and the Sigma Drive coupling.8:38 To secure the fiberglass stern tube, the builder constructs aluminum dams and uses Chockfast resin to lock the assembly into the hull.24:41 The installation includes a water-lubricated cutlass bearing, which is designed to be replaceable via access screws protected by custom aluminum tunnels during the resin pour.5:20 After an initial measurement error required welding and re-drilling a hole in the hull, the team verifies the final clearance for the folding propeller blades against the deadwood.22:38 The project emphasizes the necessity of dry-fitting components and calculating precise resin volumes to manage exothermic heat during the pour.27:49 Proper alignment and structural integrity of the shaft assembly remain critical for long-term reliability in a corrosive marine environment.

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