Home-  Sailboat-  Submarines-  ROVs-  Metal Working-  Other Stuff -  About Us

Build Log
Origami Hull
  Paul's 65ft Origami
  Steel vs Aluminum
  Getting Steel
  Cutting Darts
  Folding the Hull
  Bow and Transom
  Junk Sails
  Background Info
  Diesel Engine
  Controllable Pitch
  Other Propellers
Pilot House
Canvas Work
Gantry and Hoist
Block & Tackle
Skeg, Rudder & Helm
Deck Crane
Sand Blasting
Hatches / Portlights
Rules of Thumb


Paul Liebenberg's Origami Junk

Scale model for original double
ender, with a flush deck.

Paul's boat is a 65 foot long, twin keel so not much shorter than the 74 feet hull design that Jack Carson drew and modeled for us. 

Over the course of the build Paul's needs changed and so the boat changed too.  What started as a fast build design with a flush deck and double ends, as given way to an expansive Chinese Junk.

In many ways our plan starts where Paul's designed ended up.  As such it serves as an excellent example of our path forward.







Click to enlarge any of the
photos below.

Our thanks to Paul for
providing these.

Double keel and double chine.

Concrete poured for a work site.

The truck drives out from under
the steel.  This is 3/16 inch,
wheel abraded and primed steel.


The steel sheets are butt jointed
and tack welded together, and
then the pattern from the model
is transferred to the steel.

And Paul uses a plasma cutter to
cut along the pattern.


With one side cut out it is drug
on top of the second side so the
the pattern can be transferred


Both sides are now cut and a
stainless steel pipe has been
welded to the top of the

I-Beams are temporary welded
to both sides so they can be
turned over.


With the other side exposed the
stitch welded will be completed
on the outward facing side.


Brent Swain joins Paul to pull the
hull together in its original double
ender form. Angles have been
attached to increase the
longitudinal stiffness.

Paul and Brent pulling it together.

Lifting the ends and sides lets
gravity help close the chines.

With the darts stitch welded
together one side is done.

After the second side is done,
the two sides are joined together
about 1/4 of the way back from
the bow.

Viewed from the bow, a front
end loader and hoist pull the
halves together and upright.

More welds are added and
earlier welds that have broken
are redone as the halves close

The model sits in the foreground
and the hull continues to close.

The bow is temporarily closed to
form the original double ender.

Strong backs are added to help
close the gap between the ends
of the chine plates.

Once welds are in place, the
strong backs are removed.


The hull is jacked up and braced
in preparation for the keels.
Note the 2 inch bar on the front.


There was a small error in the
pattern that resulted in a
distortion at the sheer toward the
bow. It will be corrected later as
the deck and bulwarks go on.

Spreaders are added inside the
keels, then a pattern is made, the
holes are cut in the hull and the
keels dropped into place.

Doublers are welded in across
the chines to stiffen the hull 3/16
inch hull plate. Using 1/4 inche
plate makes this unnecessary.

In order to get more room on the
aft deck the double ender design
is abandoned in favor of a broad
transom of a Junk sailboat.

To match the Junk look, the bow
is also split open and squared.

Deck framing was machine bent to give a 6 inch arch across the
deck, and a crane was acquired to help with the plating.
Cabin tops are added

Bulwarks go on.

Companion way added.

Skeg, stern tube and rudder.

Bolt flange on rudder post.

Ruder detail.

Aft hand rails and the beginning of the aft deck canopy.

The frame is all stainless steel.

The aft deck can be fully enclosed by canvas.


Forward  bulwarks going in.

Hand rails and testing a raised
forward deck.

Forward deck goes in.

Bow roller.

Bow roller.

Covering up for the winter.

1/2 Stainless pipes round out the
edges of the cabin tops.

Hand holds added to the cabin
tops. A deck anchor winch is
acquired and will be enlarged to
support deep water anchorages.


Engine test fit onto it's bed.

Water and fuel fill ports added.

Rudder hydraulics.

Aft deck table, aft cabin light and
engine removal hatch.

Completed companion way.

Open companion way.

Completed companion way
hatch.  Aluminum hatch on a
stainless steel rail.



Aft deck escape hatch.


Kay climbs out of the forward hatch.  The cargo hatch is just

Enlarged anchor winch and the
sheet winches set where they will
be installed.

Looking forward to cabin sole
above fuel and water tanks.

Looking aft at the aft cabin berth
and the rudder post.

Pressure testing the skeg which also serves as the hull cooler for the engine.


Main mast step.

Forward mast step.

Deck framing looking aft.


Dingy support off the transom.

Portals installed for additional
light in the aft cabin.


Jack and Kay with Paul's boat and the model of Seeker.



U-joint drive shaft connected with custom adapters.