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Preventing galvanic corrosion on a custom aluminum Orion 49 requires complete electrical isolation between the aluminum hull and any dissimilar metals, such as stainless steel or bronze. The construction process utilizes Delrin bushings and washers to separate stainless steel keel pins and stanchion bases from the aluminum structure. To prevent water pooling and subsequent crevice corrosion, deck fittings are mounted on raised bases, and all lockers and deck areas are designed with drainage channels leading to scuppers. For hardware attachments where bushings are impractical, Tef-Gel serves as an isolation barrier for screws. The hull design incorporates sacrificial zinc anodes below the waterline to mitigate electrolysis.13:36 A professional surveyor from the European Certification Bureau inspects the vessel during the structural phase to verify scantlings, welding quality, and compliance with CE directives before the interior is insulated and covered.

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