Hunky Dory-Aluminum Bill of Materials

The following is a listing of the primary aluminum members required to build the Inboard Version, including their sizes, lengths, and/or square footage. The listing will require some modifications if building the Outboard or I/O Versions, but will be similar. This listing is to serve as a general guide only for cost estimating purposes and is not meant to be all inclusive. Do not use this list to purchase materials without first checking to the plans and instruction guide for options. In all cases the builder should check local sources for availability of stock sizes as well as possible substitutes. How the members are obtained from the stock and the manner in which the material is utilized can vary to suit stock sizes of materials available where the boat will be built. This is why many members are listed by square footage. In other cases, members may be made from flat bar, plate, or sheet material; it makes little difference in aluminum construction. Also, square footage or linear footage may be given for contoured members which can be cut to shape from plate or sheet stock, or could optionally be formed or bent from flat bar stock. Sizes and areas of materials include a factor for overage so that minor members not specifically noted can be obtained from scrap material.

Hull, deck, motor well plating 3/16" sheet 300 sq. ft.
Stem 1/4" plate 4 sq. ft.
Frames (unequal angles) 3" x 2" x 3/16" 60 lin. ft.
Carling (flat bar) 1/4" x 2" 50 lin. ft.
Chine bar (round bar) 1/2" dia 44 lin. ft.
Side/transom flat bar stiffeners 1/4" x 1-1/4" 125 lin. ft.
Bottom stiffeners (tee's) 1-1/2" x 1-1/4" x 1/8" 100 lin. ft.
Sheer rail (Sch. 80 pipe) 1-1/4" 60 lin. ft.