aluminum catamaran plans

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Power and Sailing Yacht Plans List Copyright 2023 Michael Kasten Updated April  2023 This page provides a list of our currently available boat plans, a link to the web page for each design, and a price for each design.  What Do Plans Cost..? Below is a list of prices for each plans package that we offer. The first group lists our Sailing Yacht Designs and the second group lists our Power Yacht Designs .  Some designs are COMPLETED and others are INCOMPLETE.      COMPLETED STOCK DESIGNS :  The Estimating Plans and Building Plans prices given below in BOLD BLACK TYPE are for a FULLY COMPLETED STOCK DESIGN , the plans for which can be shipped immediately on receipt of your order.   Please see our Stock Design web page for a description of what is included, and how our prices have been determined.    INCOMPLETE OR 'SEMI-STOCK' DESIGNS :   Prices given below in PLAIN TEXT indicate plans that are INCOMPLETE.  WHY , you may ask, have I even bothered to list INCOMPLETE designs below...? Since people's circumstances often change, it is inevitable that some boat design projects will be abandoned before they are finished, and in some cases after considerable work has been done.  This can occur as is so well described in the first few pages of Rockwell Kent’s excellent non-fiction sea story, “North by East” , or as the result of a change of fortune, failing health, or for a myriad of other reasons. A few of the INCOMPLETE designs listed below (not very many) have been developed on my own, in other words, with myself as the 'client'.  Others have been created at the behest of an individual client to explore an idea or a concept.  Either way, I believe all of the designs listed below have merit.  We offer these INCOMPLETE designs at a substantial discount versus what it would cost to develop an entirely CUSTOM design, the difference being that the 'discovery' phase of the design process has already been accomplished.  Even so, there is still quite a bit of WORK REMAINING in order to complete the Plans Packages for those INCOMPLETE designs.  The prices given below reflect our actual cost to complete the Estimating Plans or the Building Plans Package for each design, assuming there will be no changes to the design as it is presented.  If you take umbrage with the cost of our INCOMPLETE designs, I urge you to read our Learning Yacht Design web page.  If one of the designs below is "close" to what you have in mind but you would like to tweak it some, I will be pleased to provide a detailed estimate for any revisions you have in mind.  If any of these designs is of interest, please inquire .    CUSTOM YACHT DESIGN :  A new CUSTOM design will necessarily include the process of " discovery " which represents Stage I of the design process, during which all options are on the table including size, type, configuration, layout, rig, materials, etc.  By comparison, given that many of the INCOMPLETE designs listed below have already had a considerable amount of design work done, very roughly the cost to create a CUSTOM design can be on the order of some 20% to 50% greater than the prices listed for the INCOMPLETE designs below, in order to accommodate the "discovery" process on the way to achieving a completed set of Building Plans.  Is the added cost worth it...?   Yes , we believe so. Please see our article on Custom Yacht Design for our best answer to that question, where you will also find an overview of the design process itself.  Our Design Stream article additionally describes how we use CAD to best advantage throughout the design process. If a new Custom Yacht Design is of interest, please inquire for more information.    COMPLETED NC CUTTING FILES :  There are several designs below for which NC Cutting files are ALREADY DEVELOPED , in which case the price is in BOLD BLACK TYPE .    DEVELOPING NEW NC CUTTING FILES :  All other NC Cutting File prices are listed in PLAIN TEXT, and reflect our actual cost to develop NC Cutting Files for that design from scratch, in which case they can be developed for metric or imperial dimensioned materials as needed. Please see our CAD Design Stream article for more information about our NC development process.    ORDERING INFORMATION : All prices are given in US Dollars and are subject to change at any time.  To place an order, please see our contact information below. To order by fax or by mail, a PDF Order Form has been provided for your convenience.    What's Included...? Estimating Plans - Building Plans - NC Cut Files... ESTIMATING PLANS :  Since all the basic information about each of our designs is available here at our web site, and for free, we no longer offer basic Study Plans.   Instead, we offer a much more useful and complete Estimating Plans for each of the designs listed below. Our Estimating Plans include the following: Drawings:    Sail Plan / Exterior Profile Drawing Interior Profile & Arrangement Drawing (one to four sheets, depending on vessel size) Structure Drawings (one or two additional sheets, depending on vessel size)    Documents:    Drawings & Documents List Written Vessel Specification Detailed Equipment List Structural Scantling List Laminate Schedule (if needed) Structure Weight & Surface Areas Builder Short List appropriate to the specific design Cover Letters to Builders re: scope of project, etc.    Our Estimating Plans are useful for study, planning, commentary, or mark-ups in the event you want to consider variations on the layout or the rig.  Primarily though, the Estimating Plans are intended for Cost Estimating .   Considering the price lists given below, the Estimating Plans represent an outstanding bargain and include quite a lot of useful information. Our Designer's Cover Letter serves as an introduction to the builder and outlines the scope of our involvement.  Our Owner's Cover Letter is a template which you can modify as needed in order to provide an introduction to the builder; to outline your intended build timing; and to let them know what stage of completion you intend their quotation to cover. NOTE :  Estimating Plans do not contain sufficient detail for actual construction of the vessel.  However the Estimating Plans do provide enough information so that builders can provide a firm quotation for construction, and to allow a preliminary construction contract to be negotiated.    BUILDING PLANS : Prior to your construction contract being finalized, and in order to actually build the boat, the complete Building Plans will be required.  Our Building Plans include all the contents of our Estimating Plans as listed above, plus all the remaining detail drawings required for construction, including the following: Drawings:    Lines Drawing Offsets (if not CNC cut) Structural Sections Joinery Sections Joinery Details Construction Details (Several Sheets Including Hull & Deck Fittings; Ports; Doors; etc.) Spar Plans (Sail: Several Sheets Including Spar Dimensions; Spar Fitting Details; etc.) Machinery Plans (Power:  Several Sheets as Needed) Numerous Detail Drawings as Needed       Vessel Design Data, including:    Hydrostatics & Trim Stability Compliance Report Performance Analysis Hull Data for Propeller Calcs Endurance & Range Under Power    Building Plans also include a thorough review of and revision of the Equipment List and Vessel Specification in order to suit your specific equipment preferences. If the drawings or documents require further revision for your use, for example to make changes to the layout or the rig, we'll be pleased to provide an estimate for making those revisions. Please see our Stock Plans page for more information about what's included, and how we can customize a stock design to suit your requests.    CUSTOM DESIGN : We can modify any of our Stock Designs to suit a newly defined purpose, or we can work with you to create an entirely new design based on your requests. Please feel free to inquire about any modifications you may have in mind, or about creating a new Custom Design to suit your specific requirements.  In way of inspiration we have provided quite a variety of Prototype Designs , any one of which can be modified as needed to create a fully completed yacht design.    NC CUTTING FILES : Several of the Stock Designs listed below for construction in metal have already been developed for automated NC cutting of the metal parts. "NC" simply means 'Numerically Controlled' - a technology for creating pre-cut boat parts directly from the 3D design model. For details regarding the benefits of NC Cutting and to find out what's included with an NC Cutting File Package , check out our article on Our CAD Design Stream and the articles linked from there.    MORE INFO :  Please see our Site Map to quickly find any of our designs, to peruse our portfolio, and to find our articles on a variety of boat related topics.  

What Will the Boat Cost..?

This is the most difficult question of all, and one for which I do not have a ready answer.  However it is a question that ultimately does have an answer...!   For any meaningful cost discovery it is necessary to solicit actual quotations for construction from a short list of qualified builders. 

For that purpose, we offer completed ESTIMATING PLANS for several of the designs listed below, with their prices listed in BOLD BLACK TEXT .  For any designs listed below that are INCOMPLETE, we have also provided the cost to develop ESTIMATING PLANS for that design, the prices for which are given in PLAIN TEXT.

Please see the following articles for information about boat costs, and about the process of soliciting estimates from builders:

The Cost Question | Affordable Boatbuilding | Estimating Boatbuilding Costs | What Will the Design Cost..?   

SAILING YACHT PLANS  

IMPORTANT - Please see the Introduction above which describes the difference between  the prices given in BOLD BLACK TEXT vs the prices given in PLAIN TEXT below.

Please also see the AVAILABLE DISCOUNT information below.  

*  See notes below about Aluminum vessels. ** See notes below about Wooden Vessels. *** See notes below about NC Cutting Files .  

MOTOR YACHT PLANS

* See notes below about Aluminum vessels. ** See notes below about Wooden Vessels. *** See notes below about NC Cutting Files .  

AVAILABLE DISCOUNTS  

• The cost of Building Plans given above includes the cost of the Estimating Plans for that design..   
• If you order STOCK Building Plans within 90 days after purchasing STOCK Estimating Plans (for the same design), we will deduct half of what you paid for the STOCK Estimating Plans (less shipping) from your order.   
• The cost given above to complete the Building Plans for an as-yet INCOMPLETE design includes the cost to develop Estimating Plans for that design.  
• If you first arrange for completion of as-yet INCOMPLETE Estimating Plans, the subsequent cost to develop Building Plans for that design will be reduced by the full cost of having developed the Estimating Plans for that design.  In other words, the INCOMPLETE Building Plans prices given above already include the cost to develop the Estimating Plans.  
• For ALL orders, if an already completed set of STOCK NC Cutting Files are ordered along with an already completed set of STOCK Building Plans for that vessel ( both paid for in full at the same time ) we will provide a discount of 10% off your entire order.  And... this discount may be applied in addition to either of the above discount options..! Note however that this does not apply to any of our designs for which the NC Cutting Files or the Design itself remain INCOMPLETE.  

For additional clarification of the above discounts, please inquire .  

IMPORTANT DESIGN NOTES

GRP or PLYWOOD : Any of our Aluminum or Steel designs can be converted for construction in GRP or cold moulded plywood. The cost of any such revisions will be quoted separately. For more information, please inquire .

STEEL : Any Steel vessel can easily be re-specified with an aluminum structure. To convert a stock steel design to aluminum, please add 20% to the cost of the Estimating Plans or the Building Plans for that design.  Conversion of NC Cutting Files from steel to aluminum will however require a completely new set of NC cutting files, for which please inquire for an estimate.

* ALUMINUM : The Aluminum vessels listed above can only be built in steel if the design is extensively modified for that purpose in order to accommodate the added weight of the structure. For more information, please inquire .  Conversion from aluminum to steel will also require a completely new set of NC cutting files, for which please inquire for an estimate.

** WOOD : Please note that our large Wooden Vessel plans are generally priced higher, since revisions will nearly always be required in order to accommodate the differing wood species that will be available for construction, and the consequent differences in scantlings and overall weight. Those revisions (within reason) are included in the prices indicated above.

*** NC CUTTING FILES : Although a complete Building Plans set is required in order build any of these boat designs, the NC Cutting Files are entirely optional . In other words, the Building Plans are required , even if you purchase the NC Cutting Files for that design. The cost of NC Cutting Files is in addition to the cost of the Building Plans. Please see above for discount options that are available...

The NC Cutting Files shown above with prices given in BOLD BLACK TYPE have already been developed , in which case they will have been created for either metric or imperial dimensioned materials, and for either steel or aluminum (noted in parentheses).

If the vessel will be built in a location that requires changing the measurement system , and / or if there is a change from steel to aluminum or aluminum to stee l structure, then additional work will be required, the cost of which will be quoted separately and in addition to the above prices. Should such changes to any of our designs be of interest, please inquire for an estimate.   

YACHT TENDERS

Our aluminum yacht tenders are the perfect companion to any of the yachts described above.

8' to 14' Prams - Building Plans: $250 . NC Cutting Files: $250 . (The Building Plans are required. The NC Cutting File is optional. The cost of the NC Cutting file includes interacting with the cutter of your choice to assure compliance with their cutting equipment.)  

PROTOTYPE YACHT PLANS

If you don't see a design here that suits your requirements, please see our Prototypes web page for links to other designs that are either under development, or that may offer a few possible ideas in way of inspiration...

Preliminary study sketches may be available for some of our Prototype Designs. If you would like to know more about one of them, please inquire .  

NACA Foil Shaped Low Drag Aluminum Paravanes

Please see our Roll Attenuation article for more information on Paravanes for Motor Yachts.

These low-drag paravanes are balanced and are adjustable for different speeds. They make use of NACA foil shaped surfaces combined with a lead ballasted NACA foil shaped bulb. They are designed to be machined out of marine grade aluminum plate and rod so that they can be shaped, and so they are lighter for a given wing area than steel paravanes would be.

The sizes given above are conservatively rated. In other words each size can be used on a larger vessel than is indicated. It is all a matter of degree. The roll attenuation will simply be more or it will be less, as compared to that of a larger or smaller wing area.

Paravane effectiveness is a function of wing area and pole length vs. your vessel’s righting moment. With a larger the vessel the poles can be made longer, achieving greater leverage, therefore a greater effect for the same size paravane.  If you have an existing vessel on which you would like to install these paravanes, but you don't have a paravane rig, we can provide a design for the rig that will fit your boat.

For more information, please inquire .   

ORDERING PLANS...

Addresses in north america.

PAYMENT OPTIONS : If you would like to make a purchase from the above plans lists, please use our PDF Order Form or please feel free to contact me for additional information. Our payment options are as follows:

• Bank Check : For orders within the US up to USD $500 your personal check will be suitable. For orders from Canada, a money order or a cashier's check drawn on a US bank in US funds will be equally suitable. For all personal check payments we will wait until your check has cleared prior to sending out your order (for domestically issued cashier's checks or money orders, clearance takes a minimum of 7 business days after it has been deposited ).
• Pay Pal:  For orders of up to USD $1,000 payment may be made via Pay Pal.  Please inquire for details.
• Credit Card : For orders of up to USD $1,000 payment may also be made by credit card (Visa, Master Card, Amex) by using our PDF Order Form . The amount billed to your credit card will be the cost in US dollars. The cost in foreign currency will depend on the exchange rate applicable at the time of the transaction. A transaction fee of 5% will be added to all credit or debit card orders.
• Wire Transfer : For ALL amounts above USD $ 1,000, a direct wire transfer is required (most secure, fastest and least costly). Please inquire by FAX or by email for our wire transfer details. See our FAX number below, or please use our PDF Order Form where our FAX number will also be found.

Please note that all prices given on this page are subject to change at any time at my discretion.  

SHIPPING OPTIONS : For standard first class mail sent to any address in the US or Canada, or for airmail sent to Mexico, please add USD $60 to cover mailing costs. For US Priority Mail to US Addresses, please add USD $75. For US Express Mail to US addresses or for US Global Priority Mail to Canada please add USD $95. For FedEx standard overnight delivery in the US and Canada, or FedEx International Economy to Mexico please add USD $175.   

FREE DELIVERY...! Delivery via email is easy, and is encouraged. It is by far the fastest and most economical way to receive your plans. If you elect this option, delivery is FREE . If you accept delivery by email, we will send you all drawings as PDF plots, and all documents as PDF's, ready for printing and / or plotting, which is easily accomplished at your nearest copy shop.  

Addresses Elsewhere Worldwide

PAYMENT OPTIONS : If you live outside North America, our payment options are as follows:

• Bank Check : For any amount up to USD $ 1,000, if you wish to pay by cashier's check or money order, it should be drawn on a US bank in US funds. It is most secure when sending funds to use a courier service such as DHL, FedEx, EMS, UPS that provide online tracking, rather than regular postal mail delivery service. If sending a cashier's check by courier, please inquire for our physical shipping address. For all payments made by check or money order we will wait until your check has cleared prior to sending out your order (for foreign issued cashier's checks or money orders, clearance takes a minimum of 10  business days after it is deposited ).
• Credit Card : For orders of up to USD $1,000, payment may also be made by credit card (Visa, Master Card, Amex) by using our PDF Order Form . The amount billed to your credit card will be the cost in US dollars, plus shipping. The cost in foreign currency will depend on the exchange rate applicable at the time of the transaction.  A transaction fee of 5% will be added to all credit or debit card orders.
• Wire Transfer : For ALL amounts above USD $1,000, a direct wire transfer is required (most secure, fastest and least costly). Please inquire by FAX or by email for our wire transfer details. See our FAX number below, or please use our PDF Order Form where our FAX number will also be found. 

SHIPPING OPTIONS: For addresses in Japan, Korea, Australia, New Zealand, Scandinavia, England, or any country that uses the Euro Currency, please add USD $150 for 3 to 6 day delivery via US Global Priority Mail . For faster delivery by courier (DHL, FedEx, EMS) or by US Global Express Mail please add USD $250 (usually takes 3-4 business days).

Please note that regular postal mail service s of any kind are not offered to destinations other than those listed above. In most other locations, regular postal mail has proven to be extremely unreliable.  For destinations not listed above, please add USD $350 for 3 to 4 day delivery by courier (DHL, FedEx, EMS). We will select the best delivery method depending on your location.    

FREE DELIVERY...! Delivery via email is easy, and is encouraged. It is by far the fastest and most economical way to receive your plans. If you elect this option, delivery is FREE. If you accept delivery by email, we will send you all drawings as PDF plots, and all documents as PDF's, ready for printing and / or plotting, which is easily accomplished at your nearest copy shop.  

KASTEN MARINE DESIGN, INC. Email us for our mailing address or to arrange a phone appointment.

PDF Order Form  

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Aluminium sailing catamaran build

Discussion in ' Multihulls ' started by Donnavan Wright , Sep 9, 2019 .

• aluminium construction
• aluminium fabriacation
• study plans

Donnavan Wright New Member

Good day all you salty legends ! I’ve been searching the internet and came across your page . Being a metal fabricator I have put in a lot of thought about building my own aluminium sailing catamaran , 40 to 45 foot would be ideal . I have access to a cnc plasma and aluminium mig welders . Space not a problem either . Time not a problem either as I’m working an ever 6/6 day roster with a 5 year plan . I’ll be starting from scratch building the gigs and developing templates and so on , my question is do I approach a boat designer or is there a site I can download the study plans , drawings and procedures from ?  

oldmulti Senior Member

Hi Multihull Structure Thoughts thread on design net. The flowing pages have some aluminum boat details. Page 5 Banana Split 42 aluminium cat with thick skin. Page 14 Osram 7 48 foot cat, another tri. Page 20 Kat'alu 42 aluminum cat. Also Bruce Roberts does some aluminum cat plans in the size range.  

bajansailor Marine Surveyor

Here is a link to the thread mentioned by Old Multi. Multihull Structure Thoughts https://www.boatdesign.net/threads/multihull-structure-thoughts.62361/ Kat'alu is post #298. Old Multi had posted their catalogue which I will also add here, as she is a pretty neat design. It does help to illustrate though that there is a LOT of work involved in building a cat of this size. I think that Richard Woods recommends staying under 40' (or maybe even 35') unless you are building a commercial boat, as the time frame for an amateur builder will literally stretch into years.  

Attached Files:

Kat'alu 42 catalogue.pdf

Alik Senior Member

This design can be converted to aluminum. SC44 Sailing Catamaran - Designed by AM Design, Thailand http://www.amdesign.co.th/Stock_design_SC44.html  

fallguy Senior Member

bajansailor said: ↑ Here is a link to the thread mentioned by Old Multi. Multihull Structure Thoughts https://www.boatdesign.net/threads/multihull-structure-thoughts.62361/ Kat'alu is post #298. Old Multi had posted their catalogue which I will also add here, as she is a pretty neat design. It does help to illustrate though that there is a LOT of work involved in building a cat of this size. I think that Richard Woods recommends staying under 40' (or maybe even 35') unless you are building a commercial boat, as the time frame for an amateur builder will literally stretch into years. Click to expand...

jamez Senior Member

Peter Kerr has designed/built several successful alloy cats https://lizardyachts.com.au/  

guzzis3 Senior Member

If you are a really good Al welder and have access to the gear it might make sense. Just remember building the hull is at best 1/3 of the build. Also remember the time and cost to build te hulls is proportional to the weight. Personally I have never understood big bridgedeck cats. If you build an open deck cat the same weight you get longer hulls, equivalent accommodation, faster speeds and nicer motion. I guess you do get stuck with bigger rig and more expensive registration and storage fees. A 45' open deck cat would still have massive accommodations...  

guzzis3 said: ↑ If you are a really good Al welder and have access to the gear it might make sense. Just remember building the hull is at best 1/3 of the build. Also remember the time and cost to build te hulls is proportional to the weight. Personally I have never understood big bridgedeck cats. If you build an open deck cat the same weight you get longer hulls, equivalent accommodation, faster speeds and nicer motion. I guess you do get stuck with bigger rig and more expensive registration and storage fees. A 45' open deck cat would still have massive accommodations... Click to expand...

Try Berckemeyer Yacht Design | plans for modern and classic sailing yachts http://www.berckemeyer-yacht.de/yachts/New%20Yachts/BM39_dash.html An aluminum 39 footer open bridge deck cat that can also be done in ply if you want.  

BM39 dash general.jpg

Bm39 dash interior.jpg.

oldmulti said: ↑ Try Berckemeyer Yacht Design | plans for modern and classic sailing yachts http://www.berckemeyer-yacht.de/yachts/New%20Yachts/BM39_dash.html An aluminum 39 footer open bridge deck cat that can also be done in ply if you want. Click to expand...

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Slava. At 50 foot you need a good designer as the cost of materials alone will be high. ALIK of AMD designs is a good designer but there are many other designers who can do a good design. The real question you need to ask is what is your real requirements. You can have a simple chine V bottom open 50 foot bridgedeck cat built of 10 mm thick aluminum with minimal framing and tube cross beams. Or you can have a round bilge open 50 foot bridgedeck cat built of 5 mm thick aluminum with a lot of framing and tube cross beams. The more complex the design, the more expensive. There are many stock aluminum cabin bridgedeck designs in the 40 to 50 foot range from many designers. Please understand at 50 foot the design criteria to suit you is often more important than the cost of the design, as the total cost of the boat is going to be hundreds of thousands of dollars.  

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DIY Cruising Catamaran: Complete Building Guide

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A brand-new cruising catamaran can set you back a hefty amount of money. However, a DIY cruising catamaran provides a more affordable way to own your own boat. While building a large boat can be an extremely challenging and time-consuming experience, nothing beats the pleasure of bringing your own boat to life. 

To build a DIY cruising catamaran, buy good design plans, determine your budget and find a working space. Next, choose your hull material, buy supplies and start building the mast beam. Build and sheathe the hull, install bulkheads, the interior, and finally, launch the catamaran boat.

In this article, you will find a complete guide to building your own catamaran. You will also find detailed information on why you may want to consider building your catamaran and approximately how much this project would cost. Finally, we will explore the advantages and disadvantages of building a catamaran from scratch.

Why You Might Want To Build Your Own Catamaran

Most people might think that purchasing a used boat to repair and fix it up would be cheaper than a DIY cruising catamaran. But while building your own catamaran could be an enormous undertaking, it also comes with many advantages over buying something used. 

Other than the unique opportunity to create beautiful memories and experiences while cruising, sailing, and exploring beautiful coastlines, there are a number of benefits that come along with the DIY approach.  

Knowing Your Boat

Building your own catamaran provides you with intimate knowledge of your boat. You will know every corner, including where to find every bolt, wire, bulkhead, rib, hose, and support as you installed them yourself. This knowledge will enhance your confidence while at sea since you will have entrusted your life to a boat whose history you are aware of and deeply connected to.

Pride of Ownership

The satisfaction you get from crafting something with your own hands is immense. As a result, the knowledge that you built your boat from scratch will fill you with absolute pride and an immense sense of achievement. Furthermore, as an owner-builder, you get to keep and enjoy the boat for as many years as you wish.

Substantial Cost Savings

Building your catamaran will work out cheaper than buying a new or even gently used boat. Though you will likely require some additional labor since doing some things will require an extra pair of hands, if you are particularly good at DIY, you will save a significant amount of money on labor costs as a whole. 

Freedom To Create Your Own Designs

If you decide to buy a catamaran boat, it might not be easy to find one that meets your unique needs. However, instead of choosing from production boats that bear traditional and outdated designs, you can come up with an ultra-modern design or style for your catamaran. You also get to pick your layout, size, and equipment based on your taste and budget.

Great Learning Experience

Building your own boat will help you pick up numerous skills that will come in handy later when sailing your boat. As much as you might still require an expert to help you with specialized skills like carpentry or wiring, your new skills will serve you well. This will also be beneficial when it comes to your boat’s maintenance and fixing things for yourself. 

What To Look For in Catamaran Boat Designs

When deciding on the type of catamaran boat to build, you may want to choose a design that’s simple and easy to build. This is because doing so will allow you to spend a shorter time building the boat. 

You also need to have a set of requirements to guide you in choosing your design or what you might call an ideal cruising catamaran wish list. This is essential because, ultimately, you want to build a boat that offers outstanding qualities such as:

• Delivers good speed
• Affordable to own and operate
• Agile, strong, and easy to maintain
• Has a high resistance to capsizing
• Great for sailing and cruising
• Delivers a comfortable and easy motion underway
• Good handling ability and high performance under sail
• User-friendly embarking and disembarking
• Provides ample living and accommodation space 
• Presents a reasonable resale value

It’s worth noting that, in general, catamaran boats tend to offer a fair resale value mainly because of scarcity and the high price accorded to production models. So, if you build a well-constructed catamaran, you are bound to get a return that’s much higher than the cost of materials upon resale.

It’s also good to consider whether the design you settle on is from an established designer. This is significant because documentation of the building process is just as valuable when it comes to selling the boat.

How Much Would It Cost To Build Your Own Catamaran?

The cost of building your cruising catamaran will depend heavily on the size of the boat you plan to build and the skills you bring to the table. To give you an idea of probable costs, a professionally built 40 foot (12.1 m) long cruising catamaran could go for up to $300,000. 

Though building it yourself will undoubtedly be cheaper, most DIY boatbuilders tend to underestimate the expected costs. Your final costs should cover not only the cost of material and equipment but also the labor and time it would take to come up with the final product. 

If you were to build a 40-foot (12.1-meter) catamaran, your cost of materials would range between 20-30% of the total cost. Therefore, for $300,000 total, the boat’s materials would range between $60,000 and $90,000. The hull tends to range between 15-35% of the total build. Again, this depends on the finish and furniture.

But before you even start working on the DIY project, you will need to figure out where to do the work. If your home has ample space, then you can opt for a backyard building. But if you live in a small apartment, then you might want to consider renting a small garage at first and then move on to a boatyard later. This is one of the significant costs involved in building your multi-haul.  

What You Will Need

To get a clearer picture of how much the entire project would cost, let’s have a look at what else you will need to purchase.

• Good design plans
• Working space
• Ground tackle
• Matting and roving
• Equipment such as the engine, windows, rudders, deck fittings, mast, and rigging

In addition to the above, you also need to install plumbing and electricals. You may also want to consider going electric rather than using diesel. Not only will this drastically reduce your maintenance costs, but you get to use the regenerated power for all of your housing needs while sailing. 

Some catamaran boat designs help you save costs by advocating the use of less expensive corpus materials. Most of the material goes directly into making the boat, which means there is hardly any wastage on vacuum bagging . With this method, there are few molds and temporal building forms and fewer fillers to grind off as waste. All these factors reduce the time and cost it takes to build your catamaran boat.

That said, building a boat of any kind is a huge financial undertaking. As such, you still need to have the financial ability to keep building; otherwise, your project will stall or take much longer than anticipated. Instead of enjoying yourself and making memories cruising to faraway lands, you might end up spending all your time building a seemingly never-ending boat.

To reiterate, this project is more of a labor of love, given that it involves a tremendous amount of manual work. Calculating an hourly rate on the time spent building the boat and adding this cost to that of materials may make it seem a very pricey exercise. However, it is vital to understand that your time matters, and every hour you spend working for “free” should be included. 

With that in mind, you need to ensure that you are fully devoted to the boat construction project and are sure you want to do it before you begin. Stopping halfway because it seems like too much work would be incredibly costly.

How To Build a Catamaran

When it comes to building a cruising catamaran, you have 3 main options:

• You can buy an old boat and refurbish it.
• Purchase a bare hull plus deck molding for a home-boat building.
• Start from scratch and build everything, including the hull, on your own. 

As mentioned above, renovating an existing boat may end up being more costly than starting from scratch. To build a catamaran boat from scratch, follow the below step-by-step guide.

Prepare the Essentials

Before you jump into such a large project, there are several important aspects to consider:

• Buy your plans from an established catamaran designer. You can also get inexpensive, easy-to-build catamaran designs online.
• Get access to a large working space or build a shed . Depending on your climate, you may need to opt for climate control to avoid an excess of moisture in humid areas. 
• Decide on your choice of hull material. This could be fiberglass, aluminum, steel, wood, or ferroconcrete. 
• Start working on a bill of materials estimate. Include everything that you think you need to get a better idea of the initial costs.

Build the Mast Beam

Using wood and epoxy, cut and glue together the pieces of wood that will form the mast beam. Most of the work at this stage can occur in a garage since it involves building small parts. Still, the work could take up to 4 months, so be prepared to put in long hours.

Build the Boat Hull

Now, it’s time to build the boat’s hull. A catamaran comprises two hulls which are connected with a deck. Below is a short video showing how to build a hull mold:

This work requires a larger facility, so you might need to move out of the garage and into a boatyard. If you don’t have access to a larger workshop, consider building a shed where you can work as you do the construction. Make sure there’s enough room to fit the boat and also allow you to work comfortably. To cover the shed, you can use opaque white tarps. 

Sheathe the Hull

Get all the materials you require for this stage in the construction, such as lots of resin, fiberglass, and foam for use in the hull cores. You’ll also require matting and glass roving to sheath the hull . 

Sheathing helps to make the hull impervious to water and other marine borers. But first, you need to prepare the hull using a rotary sander. To make it as smooth as possible, use light, sweeping strokes. This is a very dusty task so be prepared to wear a facemask and safety goggles. 

Install the Bulkheads

Next is installing the plywood bulkheads . You might need to call in friends to help turn the hulls or use a crane. In this step, you will need to laminate the hull sides on the molded hull panels and bond them above the bulkheads. Ensure the bulkheads are snug and sealed in place.

Construct the Interior Structure

Over the next couple of months, the boat work will involve joining the hulls together with the beams that you had made back in the garage. Then, install the cuddy cabin, decks , and the cockpit . Soon the boat will start to take the shape of a catamaran.

Next, proceed to construct the major structural components such as stairs, hatches, mini-keels, and the interior. Then comes the work of fairing the boat, which is quite labor-intensive. 

Finally, it’s time to apply primer on the catamaran boat and start the paintwork. Before painting the boat, you will need to do additional sanding to finish off the two layers of primer as well as fill all the pinholes. Since it’s a large boat, the catamaran has lots of surface area; thus, the sanding could get extremely exhausting—mentally and physically—at this point.

The painting can take a while, too. The hulls are the easiest to paint, but the topsides, non-skid, as well as masking and prepping could seem never-ending. 

The final stretch involves working on the center bridge deck cabin and other final touches like installing the engines, electricals, and plumbing. This is also the time to fix the rudders, rigging, mast, windows, and deck fittings.

Launch Your Cruising Catamaran

After many months or years of hard work, your cruising catamaran is finally ready to test the waters. After lowering the boat into the water, check carefully in case there are leaks. If none, you can set up the sails and take your catamaran out for your first cruise. 

Below is a short video that takes you through the entire boat-building process:

If you don’t have deep pockets, don’t despair. It’s also possible to build an inexpensive catamaran boat, as shown in this post from the coastal passage .

The Pros of Building a Catamaran

Though it will be a costly endeavor, there are so many things to look forward to should you decide to build your own catamaran:

• It can be lots of fun.
• You get to have a new boat.
• It’s an excellent hobby for DIY enthusiasts.
• The effort is rewarding.
• It offers a great learning experience.
• You get the exact kind of boat you want.
• You can alter building plans and tailor the boat to suit your specific needs.
• It might be cheaper than buying a new boat.

The Cons of Building a Catamaran

Though there are a number of positive aspects to a DIY build, it is just as important to keep in mind that it won’t always be easy:

• Maintenance costs can be quite high.
• It’s both mentally and physically exhausting.
• It might require some technical know-how.
• It can take many months or even years to complete.
• It requires a lot of commitment to finish the DIY project.
• It might be challenging as well as expensive to get insurance.  
• You will spend almost all your free time building the boat. 

DIY Cruising Catamaran Tips and Tricks

If you are new to boat building, it would be a good idea to build a small boat first. This would give you a good indication as to whether you’d enjoy tackling a more extensive project like building a catamaran. Again, if you are the handy type, fixing your own electronics could also save you a significant amount of money. 

Here are more tips and tricks to get the most out of your DIY cruising catamaran:

• Lower your costs. Bring down your costs even further by sourcing for parts and supplies at marine surplus outlets, Craigslist, eBay, or wholesale suppliers. 
• Enhance your resale value. Most home-built boats are not easy to sell since they tend to be too customized. To enhance your resale value, it’s advisable to work with a standard design from a well-established naval architect.
• Follow the design instructions. Make sure to follow the designer’s instructions regarding the type of materials and tools to use during the build to avoid making costly mistakes.
• Maintain your original budget. Avoid any additional customizations once you have started building the boat. Using good plans and sticking to them ensures that your budget doesn’t spiral out of control.

Final Thoughts

Building a catamaran is about more than saving money. It’s fun, exciting, fulfilling, and can be a great learning experience. While it might take many months of back-breaking work, comparative shopping and sourcing for materials will help you save a lot of money. Still, at the end of it all, you’ll have a beautiful catamaran boat, all ready for your first cruising adventure.

However, if you have neither the time nor the energy to build your own catamaran from scratch, refurbishing an existing hull might prove faster and easier. It also works out much cheaper than buying a new boat.

Owner of CatamaranFreedom.com. A minimalist that has lived in a caravan in Sweden, 35ft Monohull in the Bahamas, and right now in his self-built Van. He just started the next adventure, to circumnavigate the world on a Catamaran!

One thought on “ DIY Cruising Catamaran: Complete Building Guide ”

Hello, I am a French Quebecer who is original, imaginative, creative and who finds that all boats and catamarans have a huge flaw and a very big lack of logic. I would have a brand new concept…. I am sending this message to any catamaran creator – designer to make those who have the opportunity and the intelligence to want to know about my innovative idea which will finally upset the market much richer. An idea that will totally change the concept of sailing, navigation and save so much worry!! All I would ask for is a small percentage of each sale of the new product. To be able to make me produce one when I have enough!! It is certain that like that, you just want to tell me: come on Mr. Lessard give us your idea but do not take your word to help me in return! But, if you are the kind of man to have only one word and maybe have a proof of your good faith if the realization of the project would make it… I will be very happy!! Giving it to everyone wouldn’t bother me either…. all I would like is to be able to find flax fiber (too expensive carbon) to be able to try to make my catamaran myself. Because not rich! Have a nice day and looking forward to having a message!!

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Garcia Explocat 52 review: A go-anywhere aluminium catamaran

• February 23, 2021

The new go-anywhere Garcia Explocat 52 offers an enticing combination of space, pace and rugged construction. Rupert Holmes tested the new boat for Yachting World and felt it's clear she has the potential to make easy 250 mile days in the right conditions.

Product Overview

Manufacturer:, price as reviewed:.

In recent years there have been two clear trends in serious long-term cruising yachts. Firstly catamarans have become mainstream, to the extent that professional racing sailors talk of ‘buying a catamaran’ for cruising with their families – a monohull doesn’t even enter the equation.

This trend can also be seen in ARC (Atlantic Rally for Cruisers) entries, where multihulls are increasingly common. In 2020 they accounted for 28% of the total fleet and a much higher proportion of new boats and more recent designs.

The second trend is the rapidly growing popularity of rugged metal expedition yachts. Aluminium is favoured for this as it offers good strength and stiffness without a weight penalty, especially for yachts over a critical size. That’s why many top-end racing yachts were built of aluminium before composites dominated that scene.

This is a boat that’s capable of effortlessly eating miles on a long passage. Photo: Jérôme Houyvet/Garcia Yachts

It was, therefore, surely only a matter of time before someone married these two concepts to create an aluminium expedition catamaran. Cherbourg-based Garcia Yachts has been building metal boats for almost 50 years, including Jean Luc Van Den Heede ’s 36.15 MET, in which he scored a podium finish in the inaugural Vendée Globe Race in 1989.

Equally Garcia needs no introduction as a front-runner in the development of expedition yachts, thanks to the success of the Exploration 45 that was developed with ARC founder Jimmy Cornell eight years ago. What’s less well known is that the Explocat 52 is by no means Garcia’s first aluminium catamaran.

A pair of 43-footers 15 years ago were followed by the SC48, one of which consistently posted some of the fastest passage times in the 2017/18 World ARC .

As part of the Grand Large Yachting group Garcia was also able to draw on considerable expertise from Outremer and Gunboat for its latest model, while naval architecture is by Pierre Delion, who also drew the SC48.

The Explocat 52 is therefore the product of a highly knowledgeable development team and has already attracted plenty of attention, including nomination for the 2021 European Yacht of the Year awards.

The core concept for the Explocat 52 is a robust, safe long-range yacht that offers good passagemaking speeds. A high level of comfort, both at sea – even in inclement weather – and in harbour was also a key requirement, and the boat had to be capable of being handled by a couple.

Go anywhere?

While a key marketing message for Garcia’s monohulls is ‘Nowhere you can’t go’, the company accepts this won’t apply as literally to the Explocat 52, even though the boat’s impressive speed potential will enable routing around a lot of bad weather.

Explocat 52, the ultimate aluminium exploration catamaran by Garcia Yachts

The problem is, unlike being knocked down in a monohull, capsizing a multihull is always catastrophic. There are parts of the world, especially at high latitudes in the southern hemisphere, or out of season in the north, where it could be impossible to route around potentially dangerous weather. Nevertheless, the boat is intended to stretch the boundaries that are sensible for exploring the globe with a catamaran, allowing owners to sail a lot further north and south than might be prudent with existing designs.

Rugged construction is also a benefit when venturing off the beaten track in tropical waters. If anything goes wrong while exploring a poorly-charted lagoon, for instance, a fibreglass boat may be in grave danger. Many foam sandwich hulls have surprisingly thin outer skins, which can make the structure vulnerable to abrasion, whether from coral or a concrete quay.

By contrast, the thinnest plating of the Explocat 52 is 5mm, which increases through 8, 10 and 12mm thicknesses, before reaching an enormously reassuring 14mm at the bottom of the hulls. The boat has framing of up to 14mm and is structurally engineered to eliminate flexing between the hulls.

A substantial keel with a long chord length is welded to the bottom of the hulls. They are marginally deeper than the rudders, which offers some protection, as well as providing a firm base on which to dry out on a beach. At the same time the key elements that have made Garcia’s Exploration monohulls so successful are incorporated.

These include fore and aft watertight bulkheads and upstands for through-hull fittings that enable all seacocks to be above the waterline. A skeg ahead of the saildrives and rudders provides good protection, while the rudders are large enough to offer redundancy in the event of one being lost. In addition, the top aft corner of the rudders have a sacrificial zone designed to eliminate risk of the blade puncturing the hull, or becoming jammed, if it hits an obstruction with enough force to bend the stock.

What about weight? Are metal multihulls uncommon because they’re simply too heavy? As with aluminium monohulls, where the material offers better strength/weight ratios for larger boats, around 14m/46ft overall length seems to be a transition point for catamarans.

Below that composite boats will always be lighter, but above that length aluminium is lighter for equivalent rigidity than a composite structure that doesn’t use exotic materials. At 18.9 tonnes lightship displacement the Explocat is therefore in the same league as other cruising catamarans of a similar size and indeed lighter than some.

Substantial built-in attachment points for shorelines are found at the waterline of each bow for use in extreme conditions, plus attachment points aft for a drogue

Interestingly, it’s also a similar figure to that of the Exploration 52 monohull, yet the Explocat offers a large amount of extra space and 35% more sail area. Maximum payload is a useful five tonnes. But how does that translate on the water?

Rapid exploration

Our test took place from Cherbourg on a gloriously sunny late November day, with a gusty and shifty southerly breeze varying from 7-19 knots.

It’s immediately clear the Explocat 52 picks up and sails at speeds that belie its displacement, putting it in a different league to other expedition yachts of similar length, especially when reaching.

Broad reaching at 120° TWA with full main and Code 0 in 16 knots of true wind we cruised comfortably at 10 knots, reaching an unfussed maximum of 11.8 knots, with the boat still feeling rock steady.

When the breeze picked up to 19 knots, at the design limit for the Code 0, we furled it and continued with the Solent jib instead, losing only a couple of knots of boat speed. By the time we turned upwind the wind had eased significantly, which gave a good test in conditions that can challenge cruising yachts.

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Boreal 52 boat test – The sailor’s off-roader

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In just seven knots of true wind we made 5.3 close-hauled, rising to 6.2 in 9 knots of breeze. Maximum upwind speed was 9 knots in 15 knots of true wind. However, these numbers can’t be achieved if pinching – the boat likes to be sailed fast and free, with tacking angles of at least 105°. This is hardly a surprise for a boat of this style that’s sufficiently fast to have a big impact on apparent wind angles.

Even in light airs the Explocat is surprisingly nimble in tacks, showing no hint it might miss stays, or slow enough for steering to be difficult until speed is regained on the new tack. Obviously the steering has less feel than a lightweight monohull, but there’s enough feedback for it to feel reasonably responsive and enjoyable to helm.

The shifty and gusty offshore winds were ideal for figuring out the boat’s capability across a range of wind strengths, but the mostly flat water meant we didn’t see the boat performing in a more agitated sea state.

Pete Goss – another massively experienced high-profile Garcia owner – has sailed the boat in more lively conditions. Even fully powered up he reported the lee shrouds remaining tight and there was no telltale creaking of furniture below decks, indicating no deflection of the structure despite the high loads. “It’s incredible how fast she is,” Goss says. He was also impressed by how nimbly the boat tacks.

Cockpits and steering

Much thought has gone into optimising the deck layout. The core vision is for key operations to take place in the safety and shelter of the aft cockpit. The only exceptions are preparing the main for use and hoisting/dropping spinnakers and reaching sails.

We conducted our test in south-east to south-west winds of 7-19 knots, in flat water

As standard the helm station is offset to starboard at the front of the aft cockpit. It has a two-position swinging wheel, which provides an all-round view over the top of the coachroof in its upper position. When swung inboard and lower, the helmsman gains shelter from the hard top, while being able to see forward through the bridgedeck cabin windows.

However, at the request of the owner the first boat has twin outboard helm stations. Before sailing it I’d expected to prefer this arrangement, but didn’t warm to it. Granted, you can steer from the windward side, with a good view of the jib, but the headsail luff will also be visible from the higher of the standard steering positions.

The key problem with the twin wheels is the coachroof creates a large blind spot on the other side of the boat. This has potential to create issues when manoeuvring in confined quarters such as a marina or when bailing out of an anchorage in an unexpected squall.

Mainsheet and traveller are handled right aft on the crossbeam, while the headsail, staysail and kite sheets, plus furling lines, are handled by electric Lewmar 65 winches on each side of the cockpit. Plenty of large rope bins and bags help keep lines nicely ordered.

The rig has twin headstays, with a marginally overlapping furling Solent jib on the main forestay, plus a self-tacking furling staysail. This runs on a neat Dyneema strop, instead of a more conventional but unnecessarily expensive and heavy track.

Combined with furling spinnakers and reaching sails it’s an excellent configuration that takes the hassle out of changing gear to suit widely different conditions.

The square-top mainsail has a Dyneema strop that pulls the ‘gaff’ forward to the mast track without any need for complex hooks, making it as easy to use as pin-head sails. A fuse attaching one of the mainsheet blocks to the boom is intended as a capsize prevention device if the boat is over pressed.

When the fuse blows the strop joining the block to the boom extends by two metres, immediately depowering the sail. The idea of the forward cockpit is to provide a protected position for a lookout when sailing in ice and for anchor handling. It also doubles as a well ventilated area for relaxation when at anchor in warmer climes.

It’s generally easy to move around on deck and there are decent steps at a gentle gradient between the various different levels. I also liked the cork deck – it looks surprisingly good, has great grip and is a more environmentally friendly option than teak.

There’s plenty of stowage, both in small lockers in the cockpit benches and in cavernous sail lockers at the front of each hull.

Davits are rated to take a 500kg RIB, allowing a substantial, powerful tender to be carried.

Temperature control

Alongside the rugged exterior is supremely comfortable and well thought out accommodation.

This, of course, isn’t a boat where it would be appropriate for the distinction between interior and exterior living spaces to be all but eliminated, as it is for many recent designs intended solely for hot climates. Nevertheless, the standard specification has a drop-down window each side of the door between the saloon and aft cockpit. This will help to open the saloon to the aft cockpit and improve ventilation in warm weather.

The saloon is comfortable, bright and airy, yet also has practical sea-going elements

For colder parts of the world an air extraction system vents moist and stale interior air without needing to open hatches.

The main forward saloon windows are also equipped with demisters. In the same vein, dedicated lockers for foul weather gear and boots have mechanical ventilation and heating. These features make sailing in cold and damp regions far more civilised, yet are addressed by disappointingly few manufacturers.

The aluminium shell is lined with up to 76mm of high density foam, which provides excellent thermal and acoustic insulation. As a result the boat is impressively quiet inside when under way – in the saloon you can barely hear the engines, even at cruising speed, and the high bridgedeck – it’s 85cm above the water – means we experienced no slapping of waves.

Insulation of this standard is expensive to install and doesn’t show up on photographs. Yet yachts create a cacophony of noise in heavy weather. Effective sound proofing is therefore a critical element in creating a comfortable environment, while the thermal insulation will be a benefit whether in the tropics or the Arctic.

As you’d expect, the saloon is very bright and airy, with a good almost all-round view.

The navstation forward on the port side, next to the watertight door to the forward cockpit

The biggest drawback in this respect is at the navstation, forward on the port side, as the mast support and starboard forward mullion obscure some of the view.

Also to port is a big galley that offers plenty of secure worktop space, with low fiddles, and masses of stowage. The test boat had additional fridge and freezer space in the starboard hull. Garcia says more than half its customers choose electric cooking and this boat has a microwave, electric oven and induction hob.

The company has its roots in custom boatbuilding and offers several choices for fitting out the hulls, with options for 6-10 berth arrangements, including a classic owner’s layout. The aft cabins have natural light through two hull windows, a wide aft window to the cockpit, plus opening ports aft and overhead.

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Garcia’s longstanding knowledge of creating rugged go-anywhere yachts has enabled the yard to produce one with a very enticing combination of space, pace and rugged construction. It also benefits from a high standard of finish, attention to detail and many neat touches. It’s clear the boat has the potential to make easy 250 mile days in the right conditions. At the same time it has sufficient tankage and stowage for supplies, spares and tools to give a high level of autonomy for extended periods. The owner of the first boat intends voyaging to Svalbard and, with another seven boats on order, it’s unlikely to be long before we see Explocats in many more far-flung and interesting parts of the globe.

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Specializing in building aluminum, hydrofoil assist, outboard powered catamarans

Alaskan Aluminum Power Catamarans specializes in the design and building of aluminum, hydrofoil assist, outboard powered catamarans; producing a welded aluminum boat specifically designed for operating in our rugged Alaskan environment. Each of our boats is influenced by a lifetime Alaskan resident who has spent most of his life both commercially fishing and sport fish guiding around Kodiak. They are designed by an accomplished naval architect specializing in hydrofoil assist catamarans, and each boat is built here in Alaska by a team well versed in fabricating within Alaska’s Commercial Fishing and Sport Boating industry.

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