Adriaan's construction tips.

These are the points I try to remind myself of every time I begin work.

SAFETY SAFETY SAFETY.

• ear-muffs -I really like Peltor ear protection and I use them.
• appropriate eye protection. I wear glasses all the time (cheating) and use a full face shield if its radical stuff which includes all Skillsawing and using the die-grinder or planer.
• boots - I almost never wear shoes except when I am working. Then I wear boots (this barefoot stuff is an African cultural thing - I do try not to embarrass my wife - when we go out, I wear shoes).
• always cover up every bit of flesh when welding (leather's good) - unless you want skin cancer - TIG is especially bad - UV radiation wise. Don't take chances here, and don't forget the back of your neck - reflections are as bad. Use the right welding shade number in the welding helmet. Wear welding gloves! If you are a beginner spoil yourself - save your eyes- buy an auto-darkening helmet.
• keep the work area tidy
• check the electrical cables often and get them off the floor if possible. Hang them from the ceiling rafters! Heavy, sharp-edged aluminum sheets and PVC covered electrical cables don't mix on the floor. Especially here in the backward USA where there is no mandatory ground fault protection (GFI) = earth leakage protection = trip switch. Unplug power tools as soon as you are through.

Tips

• think carefully about what you are going to do next BEFORE you do it.
• refer to the boat plans regularly as well as the designer's welding instructions, and weld it that way exactly. Don't over-weld, just as you have to resist the temptation to over-build.
• measure twice (at least) - cut once. Aluminum is expensive stuff.
• tack everything before you even think of welding a seam or fillet to completion.
• always cut out the tack welds
• back chip the root pass
• use a clean stainless steel wire brush. Keep it that way. This means degrease the alloy first and wire brush second. Don't forget to degrease the profiles too. If in doubt degrease the brush or use a new one.
• clean the TIG filler wire - at least degrease. Keep your gloves clean and oil free.