Fabricating a helm - aluminum - for utility boat, also compass/plotter interference?

KC8QVO

Petty Officer 1st Class
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Jun 19, 2012
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I am trying to come up with some ideas on building a helm for a utility boat. Is there anything to consider with aluminum - thickness, type, etc? A long time ago my dad did some upgrades to our old boat trailer with diamond plate aluminum. From what I recall it was about 1/8" thick and was pretty hard/stiff stuff. I am thinking something like that would work, just smooth and maybe even thinner? I'd like to be able to bend it easily but I also want it rigid enough that the steering wheel is solid and the electronics don't "pulse" going over waves.

My idea is to build in a plotter (flush mount) behind the steering wheel then install a flush mount compass on top (something like a ritchie helmsman or navigator combidial). I have heard of people having good luck with the garmin 740 series and it not causing any ill affects on compass headings. What about bigger units like the 820xs/840xs? I would assume any higher current electrical devices would be touchy - such as a 2 way radio on transmit (electrical current and RF at that point). Without having much space to work with it looks like the plotter and compass would be about 4-6" apart. I may be able to stretch that, though, as I am still in the design phases. Thoughts?
 

Bob_VT

Moderator & Unofficial iBoats Historian
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May 19, 2001
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Old street signs are a good source of aluminum however 1/8" is near IMPOSSIBLE to bend. Look at what the average hull thickness is and you will see. Go to any site that sells aluminum boats. It is basically sheet metal with bends/elds and rivets to make it stronger. Have you considered fiberglass or plywood and fiberglass? There are many "creations" in the restoration section of the forum.
 

Mischief Managed

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Dec 6, 2005
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I doubt the chart plotter would affect the compass much, but the beauty of the chart plotter is that you can use it to make sure it does not affect the compass, since they both display heading information at the same time. Aluminum is the best material ever for building a boat (in my opinion) and I think a welded aluminum helm would be really cool. I would think 2mm would be fine if you designed it with enough inherent stiffness. 1/8" would be over-kill. Diamond plate would suck for flush mounting. These folks do amazing boat work in aluminum, perhaps you could get some ideas: http://www.circamarine.co.nz/

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Georgesalmon

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Apr 14, 2012
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Even if you have access to a brake press diamond plate is near impossible to bend without cracking. A good thickness is .062 or .080, they are easy to find. My hummingbird 998 does affect my compass by about 20 degrees when its on but I use the heading info from that anyway, and if its off that's when I would need my compass anyway. What really affected my compass was a speaker until I moved it.
 

minuteman62-64

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Apr 12, 2011
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My boat has an aluminum console. It is made of sheet aluminum a little under 1/16" thickness (I used to know the gauge, but forgot). I built an extension for it a while back using sheet 5052 and blind rivets. The 5052 in that thickness will take a 90 degree bend with a little effort.

With the corners and the overlaps the sheet stuff will be plenty strong for your application.
 

KC8QVO

Petty Officer 1st Class
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Jun 19, 2012
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247
Awesome info. I will look at the aluminum fabricators site when I get a chance. I am not doing anything fancy, just functional. Flat plates and rivets are the construction method. I am drawing my idea up on CAD to get a perspective of the angles and component placement.
 
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