Join Date: Jan 2012
Location: British Columbia
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A jigsaw, table saw, or skill saw will cut aluminium easily. Do all your own cutting and layout, to minimize what you have to pay others for.,
A good slope on the back of your cabin makes a bubble over the companion way, and a single door on hinges ,work much better. How much slope does yours have?
A brake press can be used to fold down edges. If you do your own cutting and take it to a sheet metal shop with a brake, that shouldn't cost too much.
Aluminium doors, locked form the inside, with a lock you reach thru a vent to unlock, makes a very tough boat for a thief to break into.
Brent Swain, Boat designer, Builder, and author of "Origami Metal Boatbuilding"