The Fusion 40 "Kit Cat" is revolutionising the boatbuilding industry. This vessel has been designed from the beginning as a high performance cruising catamaran that can be stacked into 40 foot containers and freighted anywhere in the world.

This photograph shows the infusion moulded components as they would appear when removed from the container. Complete with moulded non skid and all the recesses for hatches and portlights. The components even have individual quality control certificates.

Construction Flexibilty:

By producing this modern catamaran in modules, which in turn fit in containers, it has meant delivery is simple and it has opened the doors to worldwide marketing of the Fusion 40. The cost savings on overseas shipping as deck cargo, is in excess of $40,000.00. Private contractors are available to assist with assemblies to any stage if you desire.

By producing a catamaran in sections also has great appeal to the professional boatbuilder as well as amateurs, as they can install mechanical and furniture items as they assemble, rather than working in confined spaces.
No longer are you dictated to, Fusion Catamaran Co. supplies the structural components along with the hull and deck sections but leaves the entire fitout and layout to the owner. This allows the builder to work with their preferred materials, and allows for personal preferences as to accommodation and functions. However Fusion Catamarans have a very comprehensive Multihull Construction Guide web site to support clients.
By producing the supplied components in Foam/Glass, they are weather proof and even if your build project ran into years, there will be no deterioration, shrinkage, dry rot, etc., of the components
Instead of spending 6 months gluing strips and planks, then glassing over and fairing, fairing, fairing only to finish up with a product that has small appeal to another buyer, you can now have a beautifully gelcoated, factory finish on your Catamaran, which can be assembled in as little as 12 days (4 men).
Having gelcoated, fibreglass, foam cored and production built components (to Class "A" CE Certification) provides comfort to the owners that his vessel will be highly sought after when it comes time to sell.
Also by having a worldwide marketing base through the Agent/Builder network, an owner can gain comfort in the fact that anywhere he travels he can be assured of a helping hand as well as recognition of his Fusion.
Whilst these pictures above were taken during the assembly of the test boat in Fusion's facility, the pictures at the below show assembly can be achieved in more simple surroundings.



For more information on this fabulous product, or even where the closest one to you is, please click here to contact us .



build a catamaran kit

The seafront of Cartagena in Colombia is the backdrop for two sailing vessels of different epochs and sharply contrasting character.

Against the sea wall  Galeon Bucanero , a replica of a Spanish galleon of the seventeenth century is totally at home against the fortifications of this historically significant Spanish port city.

In the foreground Chincogan 52  Sole currently circumnavigating the globe stops over en route to Panama and the Society Islands.

Over the years I've received many wonderful photos of our boats from around the world. This one is an absolute classic. Many thanks to Mike and Sarah Mason for the shot.


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Raku 44#1 launched in Brazil. See more images in the build gallery here

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We design state of the art catamarans and supply technologically advanced light-weight kit packages
to suit DIY enthusiasts.

We help you create your own dream catamaran with clever and accurate kit packages. Kit boats that deliver exciting performance, full customisation and a sophisticated modern look.

All of our catamaran kits use modern cutting-edge materials to provide the best weight-saving advantage.  



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Building a sailing catamaran.

A collection of sailing catamaran building logs, from choosing sailboat plans to yacht launch...join us on our journey

This 'glass-over-ply' sailboat is proof that a DIY'er can successfully build an ocean-going multihull cost effectivly.

Having reliable Boatbuilding Resource Books , WILL HELP fast track your decisions prior to, during and post building.

We also wanted a light sailing catamaran that we could beach with ease. This now allows us to save money on one of the biggest maintenance DIY chores, sailboat antifouling without having the costly expense of slipway fees.

Where do I start?

Plywood and Epoxy Catamaran Why both? 

pure majek catamaran

Plywood construction is the cheapest building method available and very forgiving while one hones their skills.

Finishing with a solid fiberglass outer is also a task made easier, given the amount of glassing and gluing needed during such a project. Doesn't make sense? Read more...

Talk to the sailboat designers , get to know their design types. Get on Forums and ask the 'dumb' questions. Go to marinas (not boat shows) and look for home-build yachts.

how to build a boat

"It takes a strong desire and a will to achieve. Building a large catamaran is certainly achievable". "If you want a yacht with all 'bells and whistles', keep working because it costs money...a lot of money". J Coomer

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many sailboat plans to choose from!

Is it cheaper to build or buy? There are many yacht plans to choose from, but dont kid yourself. Many have tried to do it on the cheap and their result shows. If there was a cheaper way, the sailboat designers would tell you. Afterall, they would use that reason to sell there plans!

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catamaran sailing

DIY boat projects on Pure Majek from new navigation equipment, anchoring systems, rewiring yacht electronics diagrams, AIS and much more.  Its been ten great years since launch and we look at things that have worked and those we would change. Join us and be inspired.

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goal setting, planning and building

Setting achievable goals and how to stick to them. From the planning process, what and why we did many things, importantly, things we would do differently. The following pages draw on these experiences described in far more detail in our book ' A Sailing Catamaran Building Adventure '

a sailing catamaran building adventure

‘Green power’ is climbing up the priority ladder to such an extent nowadays that some predictions of fossil fuel costs (scorned at a few years ago), are coming home to roost.


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There are a few tricks here to with respiration, thinning of the topcoat, temperature and coat thickness. All achievable by setting goals and being disciplined .

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Building catamaran Pure Majek videos

Just want videos?  Click our Youtube Channel . Over 500,000 views and counting. NO TALK videos . Thank you for your support.

Catamaran Hulls

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Catamaran Fitout

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Catamaran Internal Painting

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Bridgedeck & Turret

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External Painting

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Final Fitout

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Antifoul & Decktred

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Fitout, ready for launch

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How Much Does It Cost To Build a Catamaran? Builders Answer!

build a catamaran kit

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Owning a catamaran is one of the best ways to enjoy life; however, even a used variant of these beautiful vessels can cost up to $800,000. This is why many people consider building one from scratch, but how much can you expect to spend on the build?

It will cost between $30,000 and $300,000 to build a catamaran. Costs depend on a few factors, including the size of the boat and the overall quality of the finishing. The exact price will come down to product choices and whether a kit is used or not.

This article will look at how much you can expect to spend for every segment of the catamaran build process using a kit. First, let’s look at some of the benefits of building your own catamaran.

Cost of Building a Catamaran With Pre-Made Kits

One of the best ways to build a catamaran on your own is to use pre-made kits. The total cost of the construction can take your spending to as high as $300,000 , but the result is a vessel you can trust just as much as any from a production line.

Assembling the Kit

You can expect the following as part of the kit for a 45ft (13.72m) catamaran:

  • The panels (including hulls, cabin top, shelves, furniture, cockpit seating, etc.)
  • Daggerboard and daggerboard cases
  • Building materials (including fiberglass cloth, epoxy fillers, up to 100 gallons (378.54 liters) of epoxy, and other materials that you can use to get the construction to the paint stage)

With the kits sorted, you can get the vessel construction done up to the stage of wiring, plumbing, and other such intricacies. Schionning , Grainger , Wharram , and Oram are four of the main catamaran kits suppliers today.

The kits from Schionning will cost you around $60,000 (before shipping fees and any taxes), while those from Oram only provide quotes on request, but the prices are often similar to the numbers quoted by Schionning. None of them include construction plans in the cost, so you’ll have to pay for the plans separately.

Grainger’s kits will cost you around $130,000 . This is double the numbers from the competition. They include construction plans in the kit costs, but that’s not enough justification for the price difference—especially as you can get plans from Oram for around $6,500

Wharram offers unique polynesian style kits such as the Mana-kit for as low as $16,400 .

None of these catamaran kits manufacturers operate stateside, so you have to budget a considerable sum for shipping. Generally, the shipping costs will likely take up another $5,000, and you’ll have to budget another $1,000 in import fees.

The Building Stage

The first expense in the building stage is paying for the space for the construction. It can take around 1-3 years to complete construction for your catamaran, so you need to ensure you have the space to hold the vessel throughout the period.

The building site also has to be prepared. Concrete or asphalt surfaces are preferable, but you can level out the floor and put a tarp on dirt to give you a surface to work on without spending too much from your budget.

However, your spending on site preparation will still fall within $15,000 even without elaborate surface preparation as you’ll need ventilation, water, lighting on site, and builder’s insurance. You’ll also need a minimum 30×60 ft (6.1×18.3 m) hoop tent.

Tools you’ll need include routers, circular saw, sanders, and other such important tools for working on fiberglass. You’ll also need lots of screws and sanding paper. With $3,000, you can buy and rent all the tools you need. You’ll need lumber and aluminum pipes for the strongback and forebeam. They’ll cost around $1,100.

Other miscellaneous expenses such as cleaning supplies and other such consumables will cost you around $5,000. This is not including the materials you need for painting.

The Topside Painting Stage

Once your boat is built up, it’s time to buy more paint for the main painting stage. Technically, the painting will start right from the hull construction, but this stage is when you’ll need dozens of gallons. For the top side, you’ll need around ten gallons of Awlgrip marine paint . This will cost you around $2,500.

The paint for the high build will also cost you around $2,500 for 20 gallons (75.71 liters), including the converter and reducer. You can paint the interior enamel with five gallons of Rustoleum semi-gloss paint, which will cost around $500. The bottom paint will also cost a similar sum overall. You’ll need to budget around $2,000 for consumables like different grits of sandpapers, thinners, rollers, brushes, mixing cups, and so on.

The Sailing Parts Stage

You should expect to pay around $13,000 for an aluminum mast with Antal Batten Car Systems. The boom (also aluminum) should cost you around $2,200. The standing rigging will be around $3,000 if you choose stainless pieces with swaged fittings. The running rigging, around $2,000 for spectra-cord options. The lengths of the rigging materials have to be in line with the dimensions you have in the plans.

Winches will cost you around $6,500 for the 50st and 40st variants. Other materials you’ll need to budget for at this stage include:

  • The Clutches ($1000)
  • Blocks ($2,500)
  • Deck Organizer ($200)
  • Jib Track ($500)
  • Traveller ($1,700)
  •  Furlers ($2000-$3600)
  •  Sails ($9,000)

The Engines Stage

Catamarans are typically lightweight, so they can be powered by two 25hp engines. Yamaha is the popular manufacturer choice when picking engines, but Penta engines can also work. Alongside the engines, you’ll need to pay for the dual control and cables, as well as the fuel system (including the gauge, filler, tank, etc.). The total cost of the engines and all the other elements to make it work will cost around $12,000.

The Steering Stage

To make the steering for your catamaran, you’ll need to spend around $1,000 on rudder shafts or rods, $300 on a steering quadrant, and another $300 on steering wheels. You can make steering wheels on your own, but you’ll find it difficult to justify the time and costs.

The Electrical System Stage

At this stage, you have to pay attention to avoid increasing the boat’s weight too much. You’ll need to fit a 400 Ah house battery, which will cost around $2,000, and a lead-acid battery as your backup. Those cost around $200.

The main source of energy for the battery will typically be solar panels. A 1000w panel (costs $1,000) can serve the purpose. Don’t forget to add the solar controller (costs around $600) and a battery charger or inverter (costs around $1,000).

The wires will cost around $2,000-$3,000 depending on your postcode and whether you can buy wires in bulk. Other elements of the wiring process, like the circuit panel, heat shrink, switches, buss bar, strips, etc., will cost around $4,000.

The Lights Installation Stage

The mast headlights are already taken care of in the mast installation stage, so your focus here is the navigation lights and interior lights. These will cost around $800. You can get these installed during the wiring stage.

The Anchor Stage

When building the anchor for your 45-inch (114.3-cm) catamaran, you should expect to spend around $4,000 on all the necessary elements, including the main anchor, the stern anchor and rode, the chain or rope, the docking gear, and the windlass. The windlass will take more than half of your budget here, followed by the anchor. When buying the rope or chain, don’t forget to consider how the weight can affect your boat.

Galley Equipping Stage

The cost of this stage will be majorly determined by your choices when it comes to elements like refrigeration and cooking stoves. Pumps, water tanks, plumbing, sink and faucets, and countertops won’t cost more than $2,000. A 3.2 cubic feet (0.09 cubic meter) refrigerator, a 2-burner induction stove, and a convection oven can cost around $2,500 collectively.

The Exterior Stage

The expenses here will go towards the hatches, stanchions, lifelines, cleats, acrylic windows, trampoline net, sail covers, cockpit cushions, and locks or latches. The hatches will take the bulk of the budget as they cost around $3,000. The trampoline net and the cockpit cushion are the next big expense costing $1,200 and $800, respectively. A combination of everything else will take the total here to around $7500.

The Interior Stage

When building the interior of the boat, you’ll need to budget for the flooring, cushions (including the fabrics and zippers for coverings), wood trim, latches, hinges, etc. You can expect to spend around $4,000 on the interior, with the flooring taking more than a third of the budget.

The Heads Stage

This is when you’ll need to add the toilets, shower, sink, faucets, hoses, holding tanks, shower sumps, and other such bits. The total expense here should amount to around $2,500. This is assuming you stick with basic toilets without a lot of unnecessary features.

General Electronics Stage

This stage is very subjective, but most people will incorporate costly elements like the autopilot, chart plotter, radar, VHF, navigation instruments, AIS, and antenna. Combined, they will cost around $10,000 at the very least, but depending on your unique needs, the cost may differ a great deal.

Estimated Cost of Building a Catamaran

Based on the catamaran construction we just discussed, here is a rough estimate of what you should expect to spend overall to build a catamaran:

The kit75,000
Building supplies25,000
Sailing parts45,000
Steering parts2,000
Navigation Electronics10,000

Why Build Your Own Catamaran?

There are a few advantages to building your own vessel. They include the following:

Acquaintance With Your Boat

When you build a boat on your own, you’ll have a better handle of all the intricate elements and all the parts. You’ll know everything starting from the position of the wires to the bolts, bulkhead, rib, support, and everything else. Maintenance will be easier because you’ll know the position of all the important elements as you installed them.

Sense of Accomplishment

While it’s nice to be able to afford a catamaran off the lot from a manufacturer, there’s a sense of accomplishment with sailing out on the seas in a vessel you made. Plus, the compliments that follow will fuel the feeling, and it doesn’t take long for you to start seeing the boat as a part of your life.

Saving Some Money

Buying a new catamaran is out of the reach of most people, even with financing. And buying a used option can reduce the price a fair deal, but you can bet it will still be expensive. Cheap used options often require a lot of investment to become seaworthy again. 

Building your catamaran can help you save up to 80% of the price you’ll have to pay for a brand new vessel and up to 50% on the cost of a used one.

Getting a Newer Design

Many catamarans on the market today are based on designs that are many years old. Even newer models are often just minor tweaks to older designs as manufacturers continue to recoup their investment in the production setup. When you build your own catamaran, you can work with newer designs and also take a different approach to the more mainstream options.

Should You Build Your Catamaran?

Now you’ve got an idea of what it will cost to build your catamaran, but should you go ahead with it? It’s a subjective decision.

While there are obvious advantages to completing the build on your own (as we’ve covered above), this is a heavy project that you should only embark on if you have a proper understanding of what is required and the right skills to get the job done at every stage. You also need to have all the logistics squared off and have a trusted source of funds for the project.

If you have to hire specialists for every stage of the build, the overall cost can increase by up to 50%. When you factor all these into the equation, you may be better off saving time and energy and going for a high-quality used boat.

How Long Will It Take To Build a Catamaran?

Building your own catamaran will likely take you at least 3 years. Your catamaran construction can be completed at a pace favorable to you. If you already have the funds in place, you can finish the construction process in months. However, most DIY boatbuilders tend to take things a bit more gradually, spreading the construction across 1-3 years.

Final Thoughts

Investing in a durable catamaran you can trust in deep seas is a costly expenditure whether you’re buying one off the lot, getting a used model, or building yours from scratch. Weigh all the pros and cons to ensure you make the best decision for your specific situation, as any mistakes can prove costly. If you choose to build and get stuck midway, don’t hesitate to get professional help to remedy the situation.

If you push through the construction, the satisfaction and elation from cruising in your completed boat will linger for a long time!

Owner of CatamaranFreedom.com. A minimalist that has lived in a caravan in Sweden, 35ft Monohull in the Bahamas, and right now in his self-built Van. He just started the next adventure, to circumnavigate the world on a Catamaran!

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Time For a Catamaran Adventure

Isn't Time For Yours?

Building Your Own Catamaran

Building your own catamaran is another option to getting into your own boat. In this page we will go over the advantages, considerations, and a detailed history and journal of our boat-building adventure with Light Wave . We hope this will give you a clear picture of what lies ahead if you go this route, including:

  • Construction methods
  • 9 essential design features
  • Review of the four leading catamaran designers for home builders
  • Construction times
  • Budget: How much did it cost to build a basic cruising catamaran?
  • Layout of our catamaran, LightWave , and lots of pictures
  • Carllie’s article from September 2000 Multihulls Magazine: “The Boat Builder’s Wife “
  • Equipment outfitting
  • Radio and communication outfitting
  • Dinghy selection and considerations
  • Having a boat custom-built for you

Because of the huge dollars needed to buy a new or even a used catamaran, we would never have gotten a catamaran if we hadn’t built it ourselves.

Let’s start by saying that building any type of larger boat, especially a catamaran, can be one of the most intellectually and physically challenging things you will ever do.

It has been said that building a large boat is the closest a man can come to giving birth to a baby. In other words there is going to some discomfort and pain along the way; you will question yourself on whether this was such a good idea; it’s very difficult to reverse the decision; and though friends will support you, you will be on your own most of the time with your significant other if he/she is game.

Know your boat

You will intimately know every part of your boat. You will know where every wire, hose, bolt, bulkhead, rib, and support is because you installed them!

Pride of ownership

We have often thought what it would be like to just buy a boat from a manufacturer, and know that while owners who have spent a lot of cash (or future life to pay off the lien) their often possessive and competing-with-the Joneses could not begin to compare to our quiet glow of happiness and akinship we feel with Light Wave .

Our boat is like part of the family. So much time was spent on her that we have a major emotional investment. Every time we see our vessel – from a distance at anchor or approaching her in our marina, we say, “What a pretty boat! I can’t believe we built it!” Then that sense of accomplishment settles back in and we feel we have indeed earned the privilege of all of the beautiful experiences we have had sailing, cruising, exploring the beautiful BC Coast and much further a field (or should we say “an ocean”?).

You will be able to pay for the materials as you go and “donate” your time to the cause.

Get a newer design

Many of the production boats that are out there are designs of many years ago because the manufactures have to recoup their capital investment on the mold and production setup. When you build your own you have much newer designs to draw from.

Details on Our Boat Building Adventure

We had sailed our first boat Wave Dancer for five years and had many adventures on the British Columbia coast. In May 1996, I had just returned from a little one-week solo trip in the Gulf Islands of BC when I bought the book, The Cruising Multihull by Chris White (Future link to book review on our web site).

This is the book that got me going (Carllie was not yet convinced). I must have read it a half dozen times over the next 6 months, each time becoming more convinced that this was the way to go for our next boat. It was really still pre-internet web site days so I wrote to all the designers that were listed in the back of the book. Over the next several weeks packages of information started appearing in the mailbox (there is just something about getting packages in the mail – I guess it’s the anticipation). I would pour over these preliminary printed pages with pictures and accommodation layouts. Next, I put a few dollars down to buy the information packages and study plans from the top prospects.

I waited patiently for the study plans. It was like the night before Christmas when I was kid. Oooh the wait! Finally they came, and again I carefully scrutinized the next level of detail. Things were getting a little more serious. The top contenders were:

  • Richard Woods
  • Chris White
  • James Wharram

Click here to read my comments and reviews on their catamaran designs as well as those of Jeff Schionning.

I remember initially drooling over the Atlantic 42 by Chris White, still one of my favorite designs. It seemed to be so seaworthy (by the way if I run into about $800,000 USD any time soon, I am going to buy an Atlantic 55). The most important piece of advice that came out of the material was from Richard Woods:

“Build the smallest boat you‘d be happy with it.”
Axiom #1: The hours to build a catamaran is in almost in direct proportion to its weight.

Which brings us to Axiom #2:

Axiom #2: It takes about 1 hour to create 1 pound of finished boat.

In our case we spent 3,500 hours ( click here for full details on the construction hours ) to build a 4,000 lb. boat (just a little less than 0.9 hours per pound). If a boat’s empty weight is 8,000 lbs., it will probably take about 6,000 hours to build.

When you think about it, you can only mix and handle so much material per hour. More boat weight, more material, more hours. Sure there are some economies of scale on a bigger boat, but usually the systems become more complex and these take longer to install.

This decision process took 8 months and I figured we’d launch in 6 months. It was now January of 1997. Little did we know it would be 26 months and 3,500 hours between the two of us until we launched on June 5, 1999. We ordered the full plans and we were off and running.

We were ready to build, but where would we start the process? First of all, we live in a tiny 480 sq. ft. apartment in Vancouver. Back-yard building wasn’t exactly an option so I found a small garage nearby that we rented for 5 months.

After about 4 months in the garage, I had made all the small parts and it was time to build the hulls. This meant that we had to go larger facilities. We found space at Shelter Island Marina and Boatyard in Richmond. This is the biggest boat yard in the Vancouver area with dozens of commercial and private projects, big and small, under way.

We were out of money by then, so we sold our first boat so we could buy resin and fiberglass. It was a traumatic time as we said goodbye to our beloved Wave Dancer . We were now committed. We than had all the foam for the hull cores, barrels of resin, and huge rolls of matting and roving needed for the fiberglass skins delivered to our “domed stadium”. We kicked ourselves many times that we didn’t take a picture of this raw material stacked in one corner of the empty shed, so we could later show “before” and “after” photos. It was time to build the hulls.

Over the next several months we proceed to join the hulls with the beams I had built in the garage, and then to install the cuddy cabin, cockpit, and decks. By the spring of 1998, it was staring to look like a catamaran. Through the spring and summer of 1998, we continued with the major structural components: mini-keels, hatches, stairs, and interior. Then we went on to the very laborious work of fairing the boat before painting. Don’t under estimate that job!

By October 1998 we were ready to prime the boat and start painting. I really thought this would go quickly. I forgot that I would have to do two more complete sandings to sand off and finish the two layers of primer application. In addition we had to fill countless pinholes – a laborious process somewhat like hiking up a mountain – each time you get to what you think is the top, you see another summit!

The boat seemed to get bigger and bigger. Believe me, there is a lot of surface area on a catamaran. I clearly remember that last sanding: I had reached the end of my physical and mental endurance – I was exhausted. I was ready to move on to the next phase – any phase but more sanding!

We now started spray-painting the hulls bright yellow. It was around this time we decided on our boat name of Light Wave . The painting took over a month: the hulls being the easy part, it was the topsides, the nonskid, and all the masking and prep that seemed to take forever. Happily, the worst of the dust was gone.

By March 1999 we were in the home stretch. The center bridge deck cabin was completed so we took a week off from our paid jobs and lived on the boat in the shed so we could work all day and not waste time commuting. March, April and May were frantic months as we finished all the final touches: engine installation, rudders, windows, deck fittings, electrical, plumbing, mast, and rigging. See our outfitting page (for more details on what we picked and why, and things we would do differently now.

Initially, our electronic systems were relatively basic but included GPS and autopilot see the following link for all our electronic outfitting choices and reasoning for more details.

It was May 22, 1999 and we decided that Saturday, June 5th would be “Launch Day” so we could send invitations to all of our friends. On the Friday night before Launch Day, we still had a number of final things to do, many of them outside. Unfortunately it was pouring rain. We were tired and very wet but the boat had to go into the water next day so we persevered on till everything was ready.

The moment of truth came as Light Wave was lowered into the water. While still in the slings of the Travelift, I jumped aboard to check for leaks. Of course there weren’t any! More food and laughs and tours of the boat for all attending. It was a great day.

Emotionally drained that night, we slept in Light Wave in the water for the first time. It was another week before we actually went out for our first trip as we had to sell the shed, setup sails, and install some final deck hardware.

To sum it up, building a catamaran was a great experience. We learned a lot. Carllie and I grew closer together through it all. We had a great time doing it. We had a beautiful catamaran to show for it. Now it was time for a catamaran adventure !


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Fusion 40 Catamaran Build

7 Minute Read

Many thanks to Shane and Carmen, who are building a Fusion 40 in Australia, for agreeing to share their experiences on the project.

build a catamaran kit

Fusion Catamarans design and sell a modular marine construction kit of components: resin infused, gelcoat and fibreglass components that enable you to build your own performance cruising catamaran or outsource the work to a yard.

Can you tell us a bit about yourself and your plans. Why did you decide to self build a Fusion 40? Are you planning a big trip, for example? We decided to build a Fusion as this will be our home and we want to ensure it will meet our demands of travelling around the world Priorities are that we want this to be a fast and comfortable boat.

Why did you choose the 40? Did you sail a Fusion Cat prior to deciding? No, we have never sailed a Fusion Cat (yes you read that right, we have never sailed one and yet we are building one!) We did a lot of research and decided on the 40 because we thought it looks stylish and it has the design aspects required for an ocean-going catamaran (ie. bridge clearance and beam)

build a catamaran kit

Were there any other brands you considered? Our original plan was to purchase a Dehler mono (42ft). Then we realised we would struggle with the lean factor on lengthy ocean crossings! We looked at Schionning but didn’t like the balsa core and amount of labour involved. Fusions are foam and divinycell. We also looked at Seawind but were put off by the inability to customise the boat and the large capital outlay

Did you consider buying a second hand yacht? Yes. We initially looked at Sonra, a Fusion 40, which was built in 2010. We seriously considered the purchase however due to the engine hours, having to replace the rigging, dated electrical coupled with the capital outlay (when we weren’t yet ready to cruise) it didn’t feel like the right decision at the time

build a catamaran kit

How long will she take to build? Our estimate is approximately 3 years

Can you share some of the challenges you have faced /expect to face on a project like this? There are too many to list here! Some of the main challenges: Fatigue! Being self-motivated means long hours! Moving to a new location without our friends and family close by for support Working with nasty chemicals…boat building is a very undesirable job!   Have you made any significant modifications to the design? Is there a process to do this with Fusion? We have completely rebuilt the bows from the standard kit. Now 13 degree reverse bow adding another foot to the waterline. Increased the cockpit length and hull bridge by 2 feet. We have also modified and extended the sterns by 3 feet, including modified transoms (another 3 feet at waterline) So in a nutshell, we have made 3 major modifications to the original design (bows, bridge, transoms)

build a catamaran kit

How much space do you need for a build like this? We are currently leasing a slab at a local slipway approx 40 x 8 x 25 ft but can’t stress enough the importance of a dome cover for shelter.

In your opinion, what kind of experience is required to successfully pull off a project such as this? Ha! So many things some to mind! – Resilience – Teamwork – Planning – Diligence – Perseverance

Are you completing the build on your own or do you have a team? It’s just us! Shane and Carmen. With occasional help when required. Our mate Mark has been helping us out of late (thanks Mark!)

Can you give us an idea of the rough price differential between a self-build and a comparable manufactured cat? Differential – It’s hard to say as we are capitalising on some unique items such as the rig, sails, electrical etc. At a guess we would say the rough saving of building (as we are owner builder) vs a production boat is approx. 20%.

What are the main advantages of a self-build catamaran like this over a production cat? The main advantage is we have had the ability to modify and we have been able to increase the structural integrity of the boat to suit harsher ocean conditions

build a catamaran kit

Are there any disadvantages? Physical labour has been very taxing on our bodies! Being in a rural area has restricted our ability to secure qualified labour This build journey has meant Shane has stopped working in his trade We are always itchy and sometimes we have questioned why we are even doing this! 😂   What is the best thing about the design? You can make it what you want by being able to customise and modernise to suit current and modern designs and trends (which we have done)

Is there a design feature you don’t like? What would you change if anything? We think the hatch behind the mast looks cumbersome. It breaks up the flush look of the windows. The installation of a flush hatch is a consideration if the area is not required for the mast rotation system. This is “Pie in the Sky “ and applicable to an extended version only. If we could change the design we would alter the underwater profile from the mini keel aft to the sterns to have less camber (turn) and more width (fatter and flatter). The aim would be to provide greater volume and a smoother release.

build a catamaran kit

What are the “Must Have” options for the boat over and above the essentials? eg electric winch, engine size, folding props, heating, water maker, inverter, solar, gen set etc…. 12Vdc, 24Vdc and 240Vac systems 24V High output alternators coupled with Lithium-Ion Batteries

What are the “Nice to Haves”? – Rotating carbon fibre wing mast with a Harken Split track car system – Reefing Hooks – OneSails carbon sails – 39HP (vs standard 29HP) Yanmars – Harken Electric winch – Beautiful sports steering wheel – Coffee machine and a kick ass stereo

Which features are not worth bothering with? Integrated air-conditioning! Expensive! Washing machine (says Shane 🤣)

How will you configure the helm? Single helm station port side Hydraulic steering

How will you configure the living space – is there room for personalisation here? Galley up No gas (full electric) Full domestic appliances including induction cooktop Customised feature coffee table Swinging chart plotter No navigation table 3rd bedroom will be interchangeable to a workshop

What kind of average speed on passage are you aiming for? 11 knots. Maximum 20+ ⛵️   How is the market for second-hand self-built Fusion cats? We hear good things! We have already got brokers ringing us

What kind of finish are you aiming for in the interior? Clean, light and modern. Neutral colours and soft textures.

How is the Fusion Owner’s community? Do you get good support from Fusion? The Fusion community of owners has been amazing. Very grateful – Call out to Nev and Amanda from Bossanova. Thankyou!!

Anything else you would add to help people thinking of building a Fusion 40? Research research research and research some more. The kit is only the beginning. There is a lot of work to consider on top of assembling the kit itself. Would seriously consider buying a Fusion already semi built and refit/modify as required to save time (and frustration!)

You can follow Shane & Carmen’s progress at Sailingstraitlines.com

Or on their Instagram and Facebook page. They are posting with the following hashtag: #sailingstraitlines

build a catamaran kit

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3DM Kit – Max42SC Sailing Catamaran

Build your own max cruise 42' sailing catamaran utilizing our 3d molded (3dm) module technology. with our easy to follow instructions., the 3dm kit comes complete with hull, cabin, cabin top, bulkheads, webs and flat pack furniture panels..

build a catamaran kit

3DM Kit Max 42 Cabin and Cabin Top

build a catamaran kit

3DM Kit Max 42 SC Hull

build a catamaran kit

3DM Kit Max 42 SC

build a catamaran kit

3DM Kit Max 42 SC Webs and Bulk Heads

build a catamaran kit

3DM Kit Max 42 SC Flat Panel Furniture

Max 42 sc with daggerboards, specifications at loaded displacement of 7700kgs:.

LWL 12.8m (42ft)

  • Draft 0.540m (loaded hull)
  • Draft 1.140m (fixed rudders)
  • Draft 1.765m (boards down)

Wing deck clearance 0.8m

Beam width at waterline 1.05m

Beam to length ratio 12.2:1

Displacement 7700kg

Dry weight 5450kg

Payload 1950kg

Propulsion 2x 25HP Outboards/ 2x 30HP Inboard diesels

Mainsail 68m²

Self-tacker 30.4m²

Code-zero 78m²

Max 42 SC with Keels

Specifications at a loaded displacement of 7700kgs:.

  • Draft 1.160m (fixed mini keels)

Payload 2250kg

Propulsion 2x 30HP Inboard diesels


Performance, surfing ability.

build a catamaran kit


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    DuFlex pre-laminated panels are the main and most important material used in our kits, predominantly in the flat panel designs, however they are used in Strip-planked designs also, though to a lesser extent. These panels are 2400mm x 1200mm and are CNC routed to speed up build time on our Wildernes X Series, as well as some of our power designs.

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    I wanted lower volume, slimmer hulls with longer waterline length for performance plus a different layout with single head (to save weight and build time) plus bridge deck cabins. I was more concerned with performance than load carrying ability so the A1280s was conceived. From the day my kit arrived to launch day it was almost 3 years to the day.