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63-526: Rustler Yachts is a British yachtbuilder based in Falmouth , Cornwall , with a reputation for handbuilding high quality, semi-custom yachts. The yachts are primarily cruising-orientated designs, built from glassfibre composite , with traditional hull forms and heavily built construction. The origins of Rustler are in the mid-1960s, when Kim Holman designed the Rustler 31 for Russell Anstey of Poole (hence

126-420: A YAG based laser with a wavelength of around 1 μm. Photochemical machining, also known as photo etching, is a tightly controlled corrosion process which is used to produce complex metal parts from sheet metal with very fine detail. The photo etching process involves photo sensitive polymer being applied to a raw metal sheet. Using CAD designed photo-tools as stencils, the metal is exposed to UV light to leave

189-515: A builder should choose the most appropriate one for the boat's intended purpose. For example, a sea-going vessel needs a hull which is more stable and robust than a hull used in rivers and canals. Hull types include: Sheet metal Sheet metal is metal formed into thin, flat pieces, usually by an industrial process. Thicknesses can vary significantly; extremely thin sheets are considered foil or leaf , and pieces thicker than 6 mm (0.25 in) are considered plate, such as plate steel,

252-416: A class of structural steel . Sheet metal is available in flat pieces or coiled strips. The coils are formed by running a continuous sheet of metal through a roll slitter . In most of the world, sheet metal thickness is consistently specified in millimeters. In the U.S., the thickness of sheet metal is commonly specified by a traditional, non-linear measure known as its gauge . The larger the gauge number,

315-459: A color-coated metal sheet. Sheet metal is used in automobile and truck (lorry) bodies , major appliances , airplane fuselages and wings , tinplate for tin cans , roofing for buildings (architecture), and many other applications. Sheet metal of iron and other materials with high magnetic permeability , also known as laminated steel cores , has applications in transformers and electric machines . Historically, an important use of sheet metal

378-410: A covering of paint). Modern steel components are welded or bolted together. As the welding can be done very easily (with common welding equipment), and as the material is very cheap, it is a popular material with amateur builders. Also, amateur builders which are not yet well established in building steel ships may opt for DIY construction kits. If steel is used, a zinc layer is often applied to coat

441-431: A design pattern, which is developed and etched from the metal sheet. Perforating is a cutting process that punches multiple small holes close together in a flat workpiece. Perforated sheet metal is used to make a wide variety of surface cutting tools, such as the surform . This is a form of bending used to produce long, thin sheet metal parts. The machine that bends the metal is called a press brake . The lower part of

504-473: A laser for cutting compound shapes, but faster for repetitive shapes (for example, the grille of an air-conditioning unit). A CNC punch can achieve 600 strokes per minute. A typical component (such as the side of a computer case) can be cut to high precision from a blank sheet in under 15 seconds by either a press or a laser CNC machine. A continuous bending operation for producing open profiles or welded tubes with long lengths or in large quantities. Rolling

567-549: A punch and a die mounted in a press. The punch and die are made of hardened steel and are the same shape. The punch is sized to be a very close fit in the die. The press pushes the punch against and into the die with enough force to cut a hole in the stock. In some cases the punch and die "nest" together to create a depression in the stock. In progressive stamping , a coil of stock is fed into a long die/punch set with many stages. Multiple simple shaped holes may be produced in one stage, but complex holes are created in multiple stages. In

630-490: A series of processes in which small incremental deformation can be done in each series. Ironing is a sheet metal working or sheet metal forming process. It uniformly thins the workpiece in a specific area. This is a very useful process. It is used to produce a uniform wall thickness part with a high height-to-diameter ratio. It is used in making aluminium beverage cans. Sheet metal can be cut in various ways, from hand tools called tin snips up to very large powered shears. With

693-474: A smooth finish. In the 1960s and 1970s, particularly in Australia and New Zealand, the cheapness of ferro construction encouraged amateur builders to build hulls larger than they could afford, not anticipating that the fitting-out costs of a larger boat can be crippling. The advantages of a ferro hull are: The disadvantages are: See also : concrete ship , concrete canoe . There are many hull types, and

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756-552: A square/circle and welding the seam together. Their wall thickness has a similar (but distinct) gauge to the thickness of steel sheets. During the rolling process the rollers bow slightly, which results in the sheets being thinner on the edges. The tolerances in the table and attachments reflect current manufacturing practices and commercial standards and are not representative of the Manufacturer's Standard Gauge, which has no inherent tolerances. The equation for estimating

819-411: A very effective antifouling metal. Cupronickel may be found on the hulls of premium tugboats , fishing boats and other working boats ; and may even be used for propellers and propeller shafts . Fiberglass ( glass-reinforced plastic or GRP) is typically used for production boats because of its ability to reuse a female mould as the foundation for the shape of the boat. The resulting structure

882-400: A wooden hull provided the risk of galvanic corrosion was minimised. Fast cargo vessels once were copper-bottomed to prevent being slowed by marine fouling. GRP and ferrocement hulls are classic composite hulls, the term "composite" applies also to plastics reinforced with fibers other than glass. When a hull is being created in a female mould, the composite materials are applied to the mould in

945-400: Is a heat treatable stainless steel, but it has a lower corrosion resistance than the other grades. It is commonly used in cutlery . The only available finish is dull. Grade 430 is a popular grade, low-cost alternative to series 300's grades. This is used when high corrosion resistance is not a primary criterion. Common grade for appliance products, often with a brushed finish. Aluminium

1008-477: Is a common heat-treated structural aluminium alloy. It is weldable, corrosion resistant, and stronger than 5052, but not as formable. It loses some of its strength when welded. It is used in modern aircraft structures. Brass is an alloy of copper, which is widely used as a sheet metal. It has more strength, corrosion resistance and formability when compared to copper while retaining its conductivity. In sheet hydroforming, variation in incoming sheet coil properties

1071-567: Is a common problem for forming process, especially with materials for automotive applications. Even though incoming sheet coil may meet tensile test specifications, high rejection rate is often observed in production due to inconsistent material behavior. Thus there is a strong need for a discriminating method for testing incoming sheet material formability. The hydraulic sheet bulge test emulates biaxial deformation conditions commonly seen in production operations. For forming limit curves of materials aluminium, mild steel and brass. Theoretical analysis

1134-468: Is a process of cutting or stamping slits in alternating pattern much like the stretcher bond in brickwork and then stretching the sheet open in accordion-like fashion. It is used in applications where air and water flow are desired as well as when light weight is desired at cost of a solid flat surface. A similar process is used in other materials such as paper to create a low cost packing paper with better supportive properties than flat paper alone. Hemming

1197-404: Is a process of folding the edge of sheet metal onto itself to reinforce that edge. Seaming is a process of folding two sheets of metal together to form a joint. Hydroforming is a process that is analogous to deep drawing, in that the part is formed by stretching the blank over a stationary die . The force required is generated by the direct application of extremely high hydrostatic pressure to

1260-445: Is also utilized as a catalyst ). These metal sheets are processed through different processing technologies, mainly including cold rolling and hot rolling . Sometimes hot-dip galvanizing process is adopted as needed to prevent it from rusting due to constant exposure to the outdoors. Sometimes a layer of color coating is applied to the surface of the cold-rolled sheet to obtain a decorative and protective metal sheet, generally called

1323-411: Is applied by a team of plasterers. The cement:sand ratio is a very rich 4:1. As the hull thickness is typically 2.5 to 3 cms, ferrocement is unsuitable for boats less than about 15 metres LOA as there is a weight penalty; above that length there is no penalty. Properly plastered ferrocement boats have smooth hulls with fine lines, and amateur builders are advised to use professional plasterers to produce

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1386-490: Is carried out by deriving governing equations for determining of equivalent stress and equivalent strain based on the bulging to be spherical and Tresca's yield criterion with the associated flow rule. For experimentation circular grid analysis is one of the most effective methods. Use of gauge numbers to designate sheet metal thickness is discouraged by numerous international standards organizations. For example, ASTM states in specification ASTM A480-10a: "The use of gauge number

1449-402: Is clear in column 3 (U.S. standard for sheet and plate iron and steel 64ths inch (delta)). The thicknesses vary first by 1 ⁄ 32 inch in higher thicknesses and then step down to increments of 1 ⁄ 64 inch, then 1 ⁄ 128 inch, with the final increments at decimal fractions of 1 ⁄ 64 inch. Some steel tubes are manufactured by folding a single steel sheet into

1512-569: Is commonly used in chemical processing equipment, light reflectors, and jewelry . Grade 3003-H14 is stronger than 1100, while maintaining the same formability and low cost. It is corrosion resistant and weldable. It is often used in stampings , spun and drawn parts, mail boxes , cabinets , tanks , and fan blades. Grade 5052-H32 is much stronger than 3003 while still maintaining good formability. It maintains high corrosion resistance and weldability. Common applications include electronic chassis, tanks, and pressure vessels . Grade 6061-T6

1575-566: Is discouraged as being an archaic term of limited usefulness not having general agreement on meaning." Manufacturers' Standard Gauge for Sheet Steel is based on an average density of 41.82 lb per square foot per inch thick, equivalent to 501.84 pounds per cubic foot (8,038.7 kg/m ). Gauge is defined differently for ferrous (iron-based) and non-ferrous metals (e.g. aluminium and brass). The gauge thicknesses shown in column 2 (U.S. standard sheet and plate iron and steel decimal inch (mm)) seem somewhat arbitrary. The progression of thicknesses

1638-452: Is generally done in multiple steps called draw reductions. The greater the depth, the more reductions are required. Deep drawing may also be accomplished with fewer reductions by heating the workpiece, for example in sink manufacture. In many cases, material is rolled at the mill in both directions to aid in deep drawing. This leads to a more uniform grain structure which limits tearing and is referred to as "draw quality" material. Expanding

1701-422: Is heated and burnt by the laser beam, cutting the metal sheet. The quality of the edge can be mirror smooth and a precision of around 0.1 mm (0.0039 in) can be obtained. Cutting speeds on thin 1.2 mm (0.047 in) sheet can be as high as 25 m (82 ft) per minute. Most laser cutting systems use a CO 2 based laser source with a wavelength of around 10  μm ; some more recent systems use

1764-525: Is laid to the mould, but before the inner skin is laid. This is similar to the next type, composite, but is not usually classified as composite, since the core material in this case does not provide much additional strength. It does, however, increase stiffness, which means that less resin and fiberglass cloth can be used in order to save weight. Most fibreglass boats are currently made in an open mould, with fibreglass and resin applied by hand ( hand-lay-up method). Some are now constructed by vacuum infusion where

1827-423: Is metal working or metal forming process. In this method, stock passes through one or more pair of rolls to reduce thickness. It is used to make thickness uniform. It is classified according to its temperature of rolling: Spinning is used to make tubular (axis-symmetric) parts by fixing a piece of sheet stock to a rotating form ( mandrel ). Rollers or rigid tools press the stock against the form, stretching it until

1890-457: Is most commonly found in yachts, pontoon and power boats that are not kept permanently in the water. Aluminium yachts are particularly popular in France. A relatively expensive metal used only very occasionally in boatbuilding is cupronickel . Arguably the ideal metal for boat hulls, cupronickel is reasonably tough, highly resistant to corrosion in seawater, and is (because of its copper content)

1953-409: Is strong in tension but often needs to be either laid up with many heavy layers of resin-saturated fiberglass or reinforced with wood or foam in order to provide stiffness. GRP hulls are largely free of corrosion though not normally fireproof. These can be solid fiberglass or of the sandwich (cored) type, in which a core of balsa , foam or similar material is applied after the outer layer of fiberglass

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2016-407: Is the lightest material for building large boats (being 15–20% lighter than polyester and 30% lighter than steel). Aluminium is relatively cheap in comparison with wood or steel in most countries. In addition it is relatively easy to cut, bend and weld. Galvanic corrosion below the waterline in salt water is a serious concern, particularly in marinas where there are other conflicting metals. Aluminium

2079-435: Is the open width of a V-die or wiping die. The curling process is used to form an edge on a ring. This process is used to remove sharp edges. It also increases the moment of inertia near the curled end. The flare/burr should be turned away from the die. It is used to curl a material of specific thickness. Tool steel is generally used due to the amount of wear done by operation. It is a metal working process of removing camber,

2142-405: Is the traditional boat building material used for hull and spar construction. It is buoyant, widely available and easily worked. It is a popular material for small boats (of e.g. 6-metre (20 ft) length; such as dinghies and sailboats). Its abrasion resistance varies according to the hardness and density of the wood and it can deteriorate if fresh water or marine organisms are allowed to penetrate

2205-403: Is widely used in sheet metal form due to its flexibility, wide range of options, cost effectiveness, and other properties. The four most common aluminium grades available as sheet metal are 1100-H14, 3003-H14, 5052-H32, and 6061-T6. Grade 1100-H14 is commercially pure aluminium, highly chemical and weather resistant. It is ductile enough for deep drawing and weldable, but has low strength. It

2268-463: The D-Day Mulberry harbours . After a buzz of excitement among homebuilders in the 1960s, ferro building has since declined. Ferrocement is a relatively cheap method to produce a hull, although unsuitable for commercial mass production. A steel and iron "armature" is built to the exact shape of the hull, ultimately being covered in galvanised chicken netting. Then, on a single day, the cement

2331-410: The "shell-first" method (also called "planking first") and the "frame first" method. With "shell first", the form of the hull is determined by joining shaped planks that are fastened together, followed by reinforcing the structure with the frames (or ribs) that are fitted to the inside. With "frame first", the hull shape is established by setting up the frames on the keel and then fastening the planking on

2394-451: The 1870s, being used for shingle roofing, stamped ornamental ceilings, and exterior façades. Sheet metal ceilings were only popularly known as " tin ceilings " later as manufacturers of the period did not use the term. The popularity of both shingles and ceilings encouraged widespread production. With further advances of steel sheet metal production in the 1890s, the promise of being cheap, durable, easy to install, lightweight and fireproof gave

2457-603: The Starlight 35,and Starlight 39, the Rustler 42 was seen as the quintessential bluewater cruiser. She marked the start of an ongoing relationship with Stephen Jones (now having designed its 33, 37, 42, 44, and most recently the 57) In 2005 Rustler moved to a newly built waterside factory in Penryn. Rustler also built yachts under the Bowman brand since the acquisition of Rival Bowman in 2002, and until 2011 also produced yachts under

2520-512: The Starlight brand. In 2007, Rustler introduced the Rustler 44, an elongated, taller version of the Rustler 42 , with a raised deck saloon. In 2009, the first daysailer was introduced, the Rustler 24 , followed by the Rustler 33 in 2011. In 2014, the modern replacement for the long-keel Ruster 36 was introduced. Although the Rustler 36 is still available, the Rustler 37 offers increased hull volume and an encapsulated long fin keel, instead of

2583-428: The advances in technology, sheet metal cutting has turned to computers for precise cutting. Many sheet metal cutting operations are based on computer numerically controlled (CNC) laser cutting or multi-tool CNC punch press. CNC laser involves moving a lens assembly carrying a beam of laser light over the surface of the metal. Oxygen, nitrogen or air is fed through the same nozzle from which the laser beam exits. The metal

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2646-429: The backstop, more advanced machines control the position and angle of the stop, its height and the position of the two reference pegs used to locate the material. The machine can also record the exact position and pressure required for each bending operation to allow the operator to achieve a perfect 90 degree bend across a variety of operations on the part. Punching is performed by placing the sheet of metal stock between

2709-581: The entire hull. It is applied after sandblasting (which is required to have a cleaned surface) and before painting. The painting is usually done with lead paint (Pb 3 O 4 ). Optionally, the covering with the zinc layer may be left out, but it is generally not recommended. Zinc anodes also need to be placed on the ship's hull. Until the mid-1900s, steel sheets were riveted together. Aluminum and aluminum alloys are used both in sheet form for all-metal hulls or for isolated structural members. Many sailing spars are frequently made of aluminium after 1960. It

2772-443: The fibres are laid out and resin is pulled into the mould by atmospheric pressure. This can produce stronger parts with more glass and less resin, but takes special materials and more technical knowledge. Older fibreglass boats before 1990 were often not constructed in controlled temperature buildings leading to the widespread problem of fibreglass pox, where seawater seeped through small holes and caused delamination. The name comes from

2835-401: The final stage, the part is punched free from the "web". A typical CNC turret punch has a choice of up to 60 tools in a "turret" that can be rotated to bring any tool to the punching position. A simple shape (e.g. a square, circle, or hexagon) is cut directly from the sheet. A complex shape can be cut out by making many square or rounded cuts around the perimeter. A punch is less flexible than

2898-410: The form of a thermosetting plastic (usually epoxy , polyester, or vinylester) and some kind of fiber cloth ( fiberglass , kevlar , dynel , carbon fiber , etc.). These methods can give strength-to-weight ratios approaching that of aluminum, while requiring less specialized tools and construction skills. First developed in the mid-19th century in both France and Holland, ferrocement was also used for

2961-453: The horizontal bend, from a strip shaped material. It may be done to a finite length section or coils. It resembles flattening of leveling process, but on a deformed edge. Drawing is a forming process in which the metal is stretched over a form or die . In deep drawing the depth of the part being made is more than half its diameter. Deep drawing is used for making automotive fuel tanks, kitchen sinks, two-piece aluminum cans , etc. Deep drawing

3024-653: The long keel on the Kim Holman design. Its largest yachts to date is the Rustler 57, launched in 2019 (2021). Boat building The boat building industry provides for the design, manufacturing, repair and modification of human-powered watercrafts , sailboats , motorboats , airboats and submersibles , and caters for various demands from recreational (e.g. launches , dinghies and yachts ), commercial (e.g. tour boats , ferry boats and lighters ), residential ( houseboats ), to professional (e.g. fishing boats , tugboats , lifeboats and patrol boats ) . Wood

3087-476: The manual process in the late 17th century. The process of flattening metal sheets required large rotating iron cylinders which pressed metal pieces into sheets. The metals suited for this were lead, copper, zinc, iron and later steel. Tin was often used to coat iron and steel sheets to prevent it from rusting. This tin-coated sheet metal was called " tinplate ." Sheet metals appeared in the United States in

3150-410: The maximum bending force is, F max = k T L t 2 W {\displaystyle F_{\text{max}}=k{\frac {TLt^{2}}{W}}} , where k is a factor taking into account several parameters including friction. T is the ultimate tensile strength of the metal. L and t are the length and thickness of the sheet metal, respectively. The variable W

3213-411: The metal down the required amount to bend it through 90 degrees. Typically, a general purpose machine has an available bending force of around 25 tons per meter of length. The opening width of the lower die is typically 8 to 10 times the thickness of the metal to be bent (for example, 5 mm material could be bent in a 40 mm die). The inner radius of the bend formed in the metal is determined not by

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3276-401: The middle-class a significant appetite for sheet metal products. It was not until the 1930s and WWII that metals became scarce and the sheet metal industry began to collapse. However, some American companies, such as the W.F. Norman Corporation, were able to stay in business by making other products until Historic preservation projects aided the revival of ornamental sheet metal. Grade 304 is

3339-445: The most common of the three grades. It offers good corrosion resistance while maintaining formability and weldability . Available finishes are #2B, #3, and #4. Grade 303 is not available in sheet form. Grade 316 possesses more corrosion resistance and strength at elevated temperatures than 304. It is commonly used for pumps , valves , chemical equipment, and marine applications. Available finishes are #2B, #3, and #4. Grade 410

3402-446: The multitude of surface pits in the outer gelcoat layer which resembles smallpox. Sometimes the problem was caused by atmospheric moisture being trapped in the layup during construction in humid weather. "Composite construction" involves a variety of composite materials and methods: an early example was a timber carvel skin attached to a frame and deck beams made of iron. Sheet copper anti-fouling ("copper=bottomed") could be attached to

3465-413: The name Rustler, a play on Russell). Russell started Anstey Yachts and built the first thirty five or so. The molds were then sold on and she was built by various companies. In the early 1980s, Orion Marine and its founder Ralph Hogg began building the traditional Rustler 36 design. The Rustler 42, launched in 1999, was the first in the new direction for Rustler. Designed by Stephen Jones, designer of

3528-422: The outside. Some types of wood construction include: Either used in sheet or alternatively, plate for all-metal hulls or for isolated structural members. It is strong, but heavy (despite the fact that the thickness of the hull can be less). It is generally about 30% heavier than aluminium and somewhat more heavy than polyester . The material rusts unless protected from water (this is usually done by means of

3591-428: The press contains a V-shaped groove called the die. The upper part of the press contains a punch that presses the sheet metal down into the v-shaped die, causing it to bend. There are several techniques used, but the most common modern method is "air bending". Here, the die has a sharper angle than the required bend (typically 85 degrees for a 90 degree bend) and the upper tool is precisely controlled in its stroke to push

3654-464: The radius of the upper tool, but by the lower die width. Typically, the inner radius is equal to 1/6 of the V-width used in the forming process. The press usually has some sort of back gauge to position depth of the bend along the workpiece. The backgauge can be computer controlled to allow the operator to make a series of bends in a component to a high degree of accuracy. Simple machines control only

3717-412: The stock takes the shape of the form. Spinning is used to make rocket motor casings, missile nose cones, satellite dishes and metal kitchen funnels. Stamping includes a variety of operations such as punching, blanking, embossing, bending, flanging, and coining; simple or complex shapes can be formed at high production rates; tooling and equipment costs can be high, but labor costs are low. Alternatively,

3780-676: The thinner the metal. Commonly used steel sheet metal ranges from 30 gauge to about 7 gauge. Gauge differs between ferrous ( iron-based ) metals and nonferrous metals such as aluminum or copper. Copper thickness, for example, is measured in ounces, representing the weight of copper contained in an area of one square foot. Parts manufactured from sheet metal must maintain a uniform thickness for ideal results. There are many different metals that can be made into sheet metal, such as aluminium , brass , copper , steel , tin , nickel and titanium . For decorative uses, some important sheet metals include silver , gold , and platinum (platinum sheet metal

3843-481: The wood. Woods such as teak , totara and some cedars have natural chemicals which prevent rot whereas other woods, such as Pinus radiata , will rot very quickly. The hull of a wooden boat usually consists of planking fastened to frames and a keel. Keel and frames are traditionally made of hardwoods such as oak while planking can be oak but is more often softwood such as pine , larch or cedar . Traditional wood construction techniques can be classified into

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3906-424: The workpiece or to a bladder that is in contact with the workpiece, rather than by the movable part of a die in a mechanical or hydraulic press. Unlike deep drawing, hydroforming usually does not involve draw reductions—the piece is formed in a single step. Incremental sheet forming or ISF forming process is basically sheet metal working or sheet metal forming process. In this case, sheet is formed into final shape by

3969-401: Was in plate armor worn by cavalry , and sheet metal continues to have many decorative uses, including in horse tack . Sheet metal workers are also known as "tin bashers" (or "tin knockers"), a name derived from the hammering of panel seams when installing tin roofs. Hand-hammered metal sheets have been used since ancient times for architectural purposes. Water-powered rolling mills replaced

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