Sailing SV Delos · video

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The crew of SV Delos has begun construction on a custom aluminum expedition catamaran in Brisbane, Australia.0:21 After finalizing the design with a naval architect in New Zealand, the team commissioned a local manufacturer to CNC-cut over nine tons of aluminum plate from 3D model files.5:58 The build process involves assembling frames on a laser-aligned strongback, followed by the installation of longitudinal stringers and bridge deck plating.8:47 To prevent heat-induced metal distortion, the team employs a specific order of operations, using temporary tack welds and manual weight distribution—acting as "human ballast"—to hold components flush before final welding.16:13 During assembly, the crew identified a 18-millimeter discrepancy in the length of a keel section, which required manual modification of the pre-cut parts.23:24 The project is currently seven weeks into fabrication, with the team transitioning from frame assembly to installing internal structural components.12:29 Proper sequencing of tack welds and careful management of thermal expansion are essential to maintaining the structural integrity and flatness of aluminum hull plating.18:07

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