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How to Build an Aluminum Drift Boat

Although unsuitable for oceans voyages or journeys over large expanses of water thanks to their shallow, almost flat hulls, drift boats are highly effective for maneuvering alongside other boats to conduct repairs or to get in amongst fishing nets and lines to make minute adjustments. The lack of shelter for the boat's pilot means that drift boats should not be used in heavy weather or in any areas with high waves. Aluminum can be used to make these boats thanks to its lightweight properties. Aluminum also forms a thin coating of oxide which protects the boat from corroding in the water. This oxide coating should be removed before welding, as it is flammable.

Things You'll Need

Aluminum sheet
Felt pen
Hacksaw
Weights
Metal pole
Measuring tape
Steel brush
Welding torch

Instructions

- 1
  Draw a shield shape on your sheet of aluminum metal. This shape should be slightly longer than the length you want your drift boat to be.
- 2
  Cut the shape from the aluminum sheet using a hacksaw. A few inches along from one end of the shield shape, draw a horizontal line that cuts off the tip of the shield. Cut along this line with the hacksaw to remove the tip of the shield on one end of the shape.
- 3
  Lay a metal pole down on the floor of your workshop. Lay the shield shape on top of the pole so that the point at the top of the shield is pointing in the direction of the end of the pole.
- 4
  Weigh the sides of the shield shape down on each side without creasing the metal. Leave the weights on the aluminum shape on the pole over night until morning. Remove the weights to reveal the curved hull shape of the aluminum hull.
- 5
  Draw a curved line on the aluminum sheet using the straight edge of the bottom of the hull shape as a template. From each end of the line, draw slightly outward angled lines that reach up to the height of the finished boat. Close the shape with a horizontal line and cut it out. Repeat this with the two curved sides to create the other two sides of the drift boat.
- 6
  Rub the aluminum with a steel brush to remove the oxide, then power up the welding torch to a low heat. Press the end piece of the boat against the edge of the aluminum shield. Hold it into vertical position and run the welding torch slowly along the inside join, melting the ends of the aluminum pieces and making them merge.
- 7
  Hold the aluminum piece into place until the metal has cooled and is secure. Repeat this step with the other two pieces, using the end piece as a guide.

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