Aluminum Watercraft With Rounded Corners At The Stern

Information

  • Patent Application
  • 20250214677
  • Publication Number
    20250214677
  • Date Filed
    January 02, 2024
    a year ago
  • Date Published
    July 03, 2025
    5 months ago
Abstract
An aluminum watercraft that includes rounded port and starboard corners at the stern of the watercraft. The rounded port and starboard corners are formed by integral port and starboard corner extensions extending from the posterior of the port and starboard side walls of the watercraft's hull. During manufacture, the port and starboard corner extensions are bent and joined to a transom assembly. The deck of the watercraft extends to the transom assembly and the bent port and starboard extensions. Curved port and starboard rails are attached to the curved port and starboard corners.
Description
TECHNICAL FIELD

Embodiments of the technology relate generally to an aluminum watercraft with rounded after corners.


BACKGROUND

Recreational watercraft can be used for a variety of activities, including fishing, water sports, and other leisure activities. Recreational watercraft typically are manufactured using either fiberglass or aluminum. When such watercraft are manufactured from aluminum, at the stern the hull is welded to the transom. The areas where the port and starboard side walls of the hull are welded to the transom form corners that form substantially right angles. Alternate methods of joining the hull to the transom of an aluminum watercraft can offer advantages in the manufacturability and performance of the watercraft. Accordingly, alternate methods of manufacturing aluminum watercraft would be beneficial.


SUMMARY

In one example embodiment, the present disclosure is generally directed to a method of manufacturing an aluminum watercraft. The method may comprise: (i) cutting a port hull section from a sheet of aluminum, the port hull section comprising a port corner extension extending from a posterior of the port hull section; (ii) cutting a starboard hull section from a sheet of aluminum, the starboard hull section comprising a starboard corner extension extending from a posterior of the starboard hull extension; (iii) joining the port hull section and the starboard hull section along a hull midline to form a hull; (iv) joining a lower transom to a lower posterior edge of the hull; (v) bending and joining the port corner extension to a port side of a transom assembly; (vi) bending and joining the starboard corner extension to a starboard side of the transom assembly; and (vii) attaching an interior liner and deck to the hull and transom assembly.


In another example embodiment, the present disclosure is directed to an aluminum watercraft having rounded aft corners. The watercraft may comprise: (i) a hull comprising a port hull side wall and a starboard hull side wall; (ii) a port corner extension extending from a posterior of the port hull side wall; (iii) a starboard corner extension extending from a posterior of the starboard hull side wall; (iv) a transom assembly attached to a hull lower posterior edge of the hull; and (v) a deck attached to the hull, wherein the port corner extension is bent to attach to a port side of the transom assembly and to form a rounded port corner, and wherein the starboard corner extension is bent to attach to a starboard side of the transom assembly and to form a rounded starboard corner


The foregoing embodiments are non-limiting examples and other aspects and embodiments will be described herein. The foregoing summary is provided to introduce various concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify required or essential features of the claimed subject matter nor is the summary intended to limit the scope of the claimed subject matter.





BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate only example embodiments of an aluminum watercraft with rounded aft corners and therefore are not to be considered limiting of the scope of this disclosure. The principles illustrated in the example embodiments of the drawings can be applied to alternate methods and apparatus. Additionally, the elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Certain dimensions or positions may be exaggerated to help visually convey such principles. In the drawings, the same reference numerals used in different embodiments designate like or corresponding, but not necessarily identical, elements.



FIG. 1 illustrates a top front perspective view of a watercraft hull in accordance with an example embodiment of the disclosure.



FIG. 2 illustrates a bottom back perspective view of the watercraft hull of FIG. 1 in accordance with an example embodiment of the disclosure.



FIG. 3 illustrates a side view of the starboard section of the watercraft hull of FIG. 1 in accordance with an example embodiment of the disclosure.



FIG. 4 illustrates a top back port side perspective view of the completed watercraft in accordance with an example embodiment of the disclosure.



FIG. 5 illustrates a top back starboard side perspective view of the completed watercraft of FIG. 4 in accordance with an example embodiment of the disclosure.



FIG. 6 illustrates a method of manufacturing a watercraft in accordance with an example embodiment of the disclosure.



FIG. 7 illustrates a top front perspective view of a watercraft hull in accordance with another example embodiment of the disclosure.



FIG. 8 illustrates a bottom back perspective view of the watercraft hull of FIG. 8 in accordance with an example embodiment of the disclosure.





DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The example embodiments discussed herein are directed to an aluminum watercraft and a method of manufacturing an aluminum watercraft. In particular, the embodiments described herein provide for an aluminum watercraft that is manufactured with rounded port and starboard corners at the stern of the watercraft, which also are referred to herein as rounded aft corners. The example embodiments of the watercraft described herein are distinct from conventional aluminum watercraft that have port and starboard corners at the stern which form substantially right angles. The rounded port and starboard corners of the watercraft described herein are achieved with the use of a port corner extension and a starboard corner extension. The port and starboard corner extensions extend from side walls of the hull and are bent to form the rounded corners. The bent port and starboard corner extensions are then welded to the transom assembly. The details of the port and starboard corner extensions will be described and illustrated further below with reference to the attached drawings.


The aluminum watercraft described herein are typically used as recreational watercraft for fishing, watersports, and other leisure activities. The watercraft described herein have a hull length in the range of 10 to 30 feet and more specifically a hull length of 15 to 25 feet. The rounded corners formed at the stern of the watercraft can offer one or more advantages. First, it can be advantageous in the manufacturing of the watercraft to eliminate the welds that would normally be made at the corners of the stern where the port and starboard side walls of the hull would be joined to a conventional transom. The elimination of the welds at the corners can simplify the manufacturing process and can reduce points of stress that may form at the corners.


Second, without being bound by a particular theory, the rounded corners formed at the stern of the watercraft may improve the performance of the watercraft. Performance improvements may include one or more of handling, acceleration, and the ability of the watercraft to plane with respect to the surface of the water.


Third, the rounded corners formed at the stern of the watercraft may improve the strength of the watercraft's hull by improving the distribution of loads imposed on the hull of the boat. Improvements in strength of the watercraft's hull may be used for a variety of advantages such as handling greater loads and reducing the amount of reinforcing bracing required within the hull.


In the following paragraphs, particular embodiments will be described in further detail by way of example with reference to the drawings. In the description, well-known components, methods, and/or processing techniques are omitted or briefly described. Furthermore, reference to various feature(s) of the embodiments is not to suggest that all embodiments must include the referenced feature(s).



FIG. 1 illustrates a top front perspective view of a watercraft hull in accordance with an example embodiment of the disclosure. FIG. 2 illustrates a bottom back perspective view of the watercraft hull. FIG. 3 illustrates a side view of the starboard section of the watercraft hull. FIGS. 1-3 illustrate aspects of the watercraft hull and attached transom assembly before the interior liner and deck are attached.


Referring to FIGS. 1-3, the hull comprises a port hull section 111 and a starboard hull section 141 that have been joined along a hull midline 152 to form the hull. The port hull section 111 includes a port hull underside 114 that is substantially horizontal and a port hull side wall 110 that is substantially vertical. Similarly, the starboard hull section 141 includes a starboard hull underside 144 that is substantially horizontal and a starboard hull side wall 140 that is substantially vertical. References to horizontal and vertical herein are with respect to the watercraft oriented as it would be operated in the water. Together, the port hull underside 114 and the starboard hull underside 144 form the hull underside 150. As illustrated in FIGS. 1 and 2, a central longitudinal axis 160 of the hull is located at the midpoint between the port hull side wall 110 and the starboard hull side wall 140 as well as the midpoint between the lowest point of the hull underside 150 and the top edges of the port and starboard hull side walls.



FIG. 3 illustrates the starboard hull section 141 after it has been cut from a sheet of aluminum and before it has been joined to the port hull section 111. While not shown alone in the figures, the port hull section 111 has a configuration similar to the starboard hull section 141, but is a mirror image thereof, after the port hull section 111 has been cut from a sheet of aluminum and before it has been joined to the starboard hull section 141.


As further illustrated in FIGS. 1-3, the starboard hull section 141 includes a starboard corner extension 142 that extends from a posterior end of the starboard hull side wall 140. The starboard corner extension 142 is an integral and continuous portion of the aluminum that comprises the starboard hull section 141. In other words, as can be seen in FIG. 3, when the starboard hull section 141 is cut from a sheet of aluminum it includes the starboard corner extension 142 as an integral and continuous portion of the starboard hull section 141. In addition to extending from the posterior end of the starboard hull side wall 140, the starboard corner extension 142 comprises three edges. A starboard extension bottom edge 146 extends from a bottom of the starboard hull side wall 140 to a bottom corner of the starboard corner extension 142. A starboard extension distal edge 148 extends from the starboard extension bottom edge 146 at the bottom corner to a top corner of the starboard corner extension 142. Lastly, a starboard extension top edge 147 extends from the starboard extension distal edge 148 to a top of the starboard hull side wall 140.


Similarly, the port hull section 111 includes a port corner extension 112 that extends from a posterior end of the port hull side wall 110. The port corner extension 112 is an integral and continuous portion of the aluminum that comprises the port hull section 111. In other words, when the port hull section 111 is cut from a sheet of aluminum it includes the port corner extension 112 as an integral and continuous portion of the port hull section 111. In addition to extending from the posterior end of the port hull side wall 110, the port corner extension 112 comprises three edges. A port extension bottom edge 116 extends from a bottom of the port hull side wall 110 to a bottom corner of the port corner extension 112. A port extension distal edge 118 extends from the port extension bottom edge 116 at the bottom corner to a top corner of the port corner extension 112. Lastly, a port extension top edge 117 extends from the port extension distal edge 118 to a top of the port hull side wall 110.


As further illustrated in FIGS. 1 and 2, a transom assembly is attached at the posterior of the hull. The transom assembly comprises an upper transom 130 that has a substantially vertical orientation, a transom step 132 that has a substantially horizontal orientation, a lower transom 134 that has a substantially vertical orientation, a port transom wing 136 that has a substantially horizontal orientation, and a starboard transom wing 146 that has a substantially horizontal orientation. The inward and outward major faces of the upper transom 130 are substantially perpendicular to the central axis 160 with the central axis passing through the center of the inward and outward major faces of the upper transom 130. The lower transom 134 of the transom assembly attaches to the hull at the hull lower posterior edge 151. The components of the transom assembly can be one or more discrete elements that are welded together. Typically, the upper transom 130, the transom step 132, and the lower transom 134 are formed from a single integral material with the port and starboard transom wings 136 and 146 being welded to the transom step 132 and the lower transom 134. The transom assembly is typically aluminum, although other materials and composites can be used for the transom assembly.


Prior art aluminum watercraft generally include an upper transom that extends across the entirety of the stern and is welded to the side walls of the hull at the aft corners of the watercraft. This approach in prior art aluminum watercraft results in aft corners that are substantially right angles. In contrast, as illustrated in FIGS. 1 and 2, the watercraft of the embodiments disclosed herein utilize the port corner extension 112 and the starboard corner extension 142 for attachment to the upper transom 130. Specifically, the port corner extension 112 and the starboard corner extension 142 are bent toward the central longitudinal axis 160 to form rounded aft corners, thereby eliminating the welds that would typically be made at the aft corners. After bending, the port corner extension 112 attaches to the port side of the transom assembly. Specifically, a port extension distal edge 118 is welded to a port side edge of the upper transom 130 and a port extension bottom edge 116 is welded to an outer edge of the port transom wing 136. Similarly, after bending, the starboard corner extension 142 attaches to the starboard side of the transom assembly. Specifically, a starboard extension distal edge 148 is welded to a starboard side edge of the upper transom 130 and a starboard extension bottom edge 146 is welded to an outer edge of the starboard transom wing 138.


Referring now to FIGS. 4 and 5, illustrations are provided of a completed watercraft that includes the hull of FIGS. 1-3 in accordance with the embodiments disclosed herein. FIG. 4 shows a top posterior port side perspective view of the completed watercraft and FIG. 5 shows a top posterior starboard side perspective view of the completed watercraft.



FIG. 4 illustrates the port hull side wall 110 and the port corner extension 112 that were described previously. Also visible in FIG. 4 is the rounded aft corner formed by the port corner extension 112 as it is bent from the port hull side wall 110 toward the transom assembly where a motor is attached to the watercraft. A deck 103 of the watercraft extends from a cabin area to the port corner extension 112. A port gunnel 113 is shown at the top of the port hull side wall 110. In prior art watercraft, a gunnel would typically extend to the aft corner where it would meet a transom that extends across the stern of the boat. However, in the example watercraft herein, the port gunnel 113 terminates before reaching the stern and terminates proximate to the region where the port hull side wall 110 transitions to the port corner extension 112. In the example watercraft of FIG. 4, the deck 103 extends across the remaining area between the termination of the port gunnel 113 and the port corner extension 112. Additionally, a port rail 115 extends along and proximate to a top of the port hull side wall 110 and includes a resilient material, such as rubber or a polymer, that protects the watercraft from impacts. The port rail 115 continues along the rounded aft corner formed by the port corner extension 112 until reaching the transom assembly. The curved portion of the port rail 115 located at the port corner extension 112 can be formed by a curved rigid port extrusion 119 that attaches to the port corner extension 112 and supports the resilient material.



FIG. 5 illustrates the starboard hull side wall 140 and the starboard corner extension 142 that were described previously. Also visible in FIG. 5 is the rounded aft corner formed by the starboard corner extension 142 as it is bent from the starboard hull side wall 140 toward the transom assembly where the motor is attached to the watercraft. The deck 103 of the watercraft extends from a cabin area to the starboard corner extension 142. A starboard gunnel 143 is shown at the top of the starboard hull side wall 140. In prior art watercraft, a gunnel would typically extend to the aft corner where it would meet a transom that extends across the stern of the boat. However, in the example watercraft herein, the starboard gunnel 143 terminates before reaching the stern and terminates proximate to the region where the starboard hull side wall 140 transitions to the starboard corner extension 142. In the example watercraft of FIG. 5, the deck 103 extends across the remaining area between the termination of the starboard gunnel 143 and the starboard corner extension 142. Additionally, a starboard rail 145 extends along and proximate to a top of the starboard hull side wall 140 and includes a resilient material, such as rubber or a polymer, that protects the watercraft from impacts. The starboard rail 145 continues along the rounded aft corner formed by the starboard corner extension 142 until reaching the transom assembly. The curved portion of the starboard rail 145 located at the starboard corner extension 142 can be formed by a curved rigid starboard extrusion 149 that attaches to the starboard corner extension 142 and supports the resilient material.


Referring now to FIG. 6, an example method 600 is illustrated for manufacturing a watercraft in accordance with the embodiments disclosed herein. Method 600 of FIG. 6 is a non-limiting example and in alternate embodiments certain operations of the method may be performed in a different sequence, modified, combined, performed in parallel, or omitted. Method 600 is intended to illustrate the unique aspects of the embodiments disclosed herein and is not intended to capture minor manufacturing aspects generally known to those in this field.


Beginning with operation 605 of FIG. 6, a port hull section having a port corner extension extending from a posterior of the section is cut from a sheet of aluminum. Similarly, a starboard hull section having a starboard corner extension extending from a posterior of the section is cut from a sheet of aluminum. In operation 610, the port hull section and starboard hull section are joined at a hull midline to form a watercraft hull. The two sections may be joined by welding, fasteners, or a combination of welding and fasteners. Additionally, the hull can be shaped using molds or templates to form a bow and starboard and port side walls of the watercraft hull. In operation 612 of example method 600, a port gunnel is attached to the top of the port hull side wall and a starboard gunnel is attached to the top of the starboard hull side wall. In alternate embodiments, operation 612 may be performed at a different time in manufacturing the watercraft.


Operations 615 and 620 of example method 600 relate to assembling and attaching the transom assembly to the watercraft. As explained previously, the transom assembly may include an upper transom, a transom step, a lower transom, a port transom wing, and a starboard transom wing. In operation 615, the port transom wing is welded to a port side of the transom step and lower transom. Similarly, the starboard transom wing is welded to a starboard side of the transom step and the lower transom. Once the transom assembly is assembled, in operation 620, the lower transom is welded to a lower posterior edge of the hull. In other embodiments, the assembling of the transom assembly and the attachment of the transom assembly to the hull may occur in a different sequence of steps. For example, the lower transom alone could be attached to the hull followed by attaching the other components of the transom assembly.


In operation 625, the rounded aft corners are formed by bending the port corner extension and the starboard corner extension toward the central longitudinal axis of the watercraft. In operation 630, the transom assembly is welded to the port and starboard corner extensions. Specifically, a port extension distal edge is welded to a port side edge of the upper transom and a port extension bottom edge is welded to an outer edge of the port transom wing. Similarly, after bending, the starboard corner extension is welded to the starboard side of the transom assembly. Specifically, a starboard extension distal edge is welded to a starboard side edge of the upper transom and a starboard extension bottom edge is welded to an outer edge of the starboard transom wing.


In operation 635, interior structural parts, such as one or more brace plates may be attached to the inner surface of the hull and/or transom assembly. After attaching interior structural parts, in operation 640, an interior liner for sealing and for buoyancy is attached to the inner surface of the hull. In operation 645, the deck is attached to the hull to complete the outer structure of the watercraft. Lastly, in operation 650, a rail is attached along the outer perimeter of the watercraft extending along the starboard hull side wall and the port hull side wall. Unlike prior art aluminum watercraft, the rounded extrusions can attach to the starboard corner extension and the port corner extension for continuing the rail around the curved aft corners to the transom assembly.



FIGS. 7 and 8 illustrate another embodiment in which the shape of the transom differs in that it includes a recessed portion. In contrast to the flat upper transom illustrated in FIGS. 1 and 2, in the embodiment of FIGS. 7 and 8 a central portion of the upper transom is recessed toward the interior of the watercraft. As provided in the following description, the features of the hull and transom assembly of FIGS. 7 and 8 are similar to those of the embodiment in FIGS. 1 and 2. Additionally, the manufacturing method described in FIG. 6 may be applied to manufacture a watercraft having the hull and transom assembly illustrated in FIGS. 7 and 8. FIG. 7 illustrates a top front perspective view of a watercraft hull in accordance with an example embodiment of the disclosure. FIG. 8 illustrates a bottom back perspective view of the watercraft hull.


As illustrated in FIGS. 7 and 8, the hull comprises a port hull section 711 and a starboard hull section 741 that have been joined along a hull midline 752 to form the hull. The port hull section 711 includes a port hull underside 714 that is substantially horizontal and a port hull side wall 710 that is substantially vertical. Similarly, the starboard hull section 741 includes a starboard hull underside 744 that is substantially horizontal and a starboard hull side wall 740 that is substantially vertical. References to horizontal and vertical herein are with respect to the watercraft oriented as it would be operated in the water. Together, the port hull underside 714 and the starboard hull underside 744 form the hull underside 750. As illustrated in FIGS. 7 and 8, a central longitudinal axis 760 of the hull is located at the midpoint between the port hull side wall 710 and the starboard hull side wall 740 as well as the midpoint between the lowest point of the hull underside 750 and the top edges of the port and starboard hull side walls.


As further illustrated in FIGS. 7 and 8, the starboard hull section 741 includes a starboard corner extension 742 that extends from a posterior end of the starboard hull side wall 740. The starboard corner extension 742 is an integral and continuous portion of the aluminum that comprises the starboard hull section 741. In other words, when the starboard hull section 741 is cut from a sheet of aluminum it includes the starboard corner extension 742 as an integral and continuous portion of the starboard hull section 741. In addition to extending from the posterior end of the starboard hull side wall 740, the starboard corner extension 742 comprises three edges. A starboard extension bottom edge 746 extends from a bottom of the starboard hull side wall 740 to a bottom corner of the starboard corner extension 742. A starboard extension distal edge 748 extends from the starboard extension bottom edge 146 at the bottom corner to a top corner of the starboard corner extension 742. Lastly, a starboard extension top edge 747 extends from the starboard extension distal edge 748 to a top of the starboard hull side wall 740.


Similarly, the port hull section 711 includes a port corner extension 712 that extends from a posterior end of the port hull side wall 710. The port corner extension 712 is an integral and continuous portion of the aluminum that comprises the port hull section 711. In other words, when the port hull section 711 is cut from a sheet of aluminum it includes the port corner extension 712 as an integral and continuous portion of the port hull section 711. In addition to extending from the posterior end of the port hull side wall 710, the port corner extension 712 comprises three edges. A port extension bottom edge 716 extends from a bottom of the port hull side wall 710 to a bottom corner of the port corner extension 712. A port extension distal edge 718 extends from the port extension bottom edge 716 at the bottom corner to a top corner of the port corner extension 712. Lastly, a port extension top edge 717 extends from the port extension distal edge 718 to a top of the port hull side wall 710.


As further illustrated in FIGS. 7 and 8, a transom assembly is attached at the posterior of the hull. The transom assembly comprises an upper transom 730 that has a substantially vertical orientation, a transom step 732 that has a substantially horizontal orientation, a lower transom 734 that has a substantially vertical orientation, a port transom wing 736 that has a substantially horizontal orientation, and a starboard transom wing 746 that has a substantially horizontal orientation. In contrast to the flat shape of the upper transom 130 of FIGS. 1 and 2, the upper transom 730 of FIGS. 7 and 8 has a shape that is recessed toward the interior of the watercraft. Specifically, a central portion of the upper transom 730 is recessed inward toward the interior of the watercraft. On the port and starboard edges of the central portion of the upper transom 730 are oblique portions that extend backward away from the interior of the watercraft. The port and starboard oblique portions of the upper transom 730 attach to the port extension distal edge 718 and the starboard extension distal edge 748, respectively. The inward and outward major faces of the central portion of the upper transom 730 are substantially perpendicular to the central axis 760, whereas the port and starboard oblique portions of the upper transom 730 are oblique to the central axis 760.


The lower transom 734 of the transom assembly attaches to the hull at the hull lower posterior edge 751. The components of the transom assembly can be one or more discrete elements that are welded together. Typically, the upper transom 730, the transom step 732, and the lower transom 734 are formed from a single integral material with the port and starboard transom wings 736 and 746 being welded to the transom step 732 and the lower transom 734. The transom assembly is typically aluminum, although other materials and composites can be used for the transom assembly.


Similar to the embodiment of FIGS. 1 and 2, the embodiment of FIGS. 7 and 8 is distinct from prior art aluminum watercraft in which an upper transom extends across the entirety of the stern and is welded to the side walls of the hull at the aft corners of the watercraft. This approach in prior art aluminum watercraft results in aft corners that are substantially right angles. In contrast, in the watercraft hull of FIGS. 7 and 8, the port corner extension 712 and the starboard corner extension 742 attach to the upper transom 730. Specifically, the port corner extension 712 and the starboard corner extension 742 are bent toward the central longitudinal axis 760 to form rounded aft corners, thereby eliminating the welds that would typically be made at the aft corners. After bending, the port corner extension 712 attaches to the port side of the transom assembly. Specifically, a port extension distal edge 718 is welded to a port side edge of the upper transom 730 and a port extension bottom edge 716 is welded to an outer edge of the port transom wing 736. Similarly, after bending, the starboard corner extension 742 attaches to the starboard side of the transom assembly. Specifically, a starboard extension distal edge 748 is welded to a starboard side edge of the upper transom 730 and a starboard extension bottom edge 746 is welded to an outer edge of the starboard transom wing 738.


For any figure shown and described herein, one or more of the components may be omitted, added, repeated, and/or substituted. Additionally, it should be understood that in certain cases components of the example watercraft can be combined or can be separated into subcomponents. Accordingly, embodiments shown in a particular figure should not be considered limited to the specific arrangements of components shown in such figure. Further, if a component of a figure is described but not expressly shown or labeled in that figure, the label used for a corresponding component in another figure can be inferred to that component. Conversely, if a component in a figure is labeled but not described, the description for such component can be substantially the same as the description for the corresponding component in another figure.


With respect to the example methods described herein, it should be understood that in alternate embodiments, certain operations of the methods may be performed in a different order, may be performed in parallel, or may be omitted. Moreover, in alternate embodiments additional steps may be added to the example methods described herein. Accordingly, the example methods provided herein should be viewed as illustrative and not limiting of the disclosure.


Terms such as “first”, “second”, “top”, “bottom”, “side”, “distal”, “proximal”, and “within” are used merely to distinguish one component (or part of a component or state of a component) from another. Such terms are not meant to denote a preference or a particular orientation, and are not meant to limit the embodiments described herein. In the example embodiments described herein, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.


The terms “a,” “an,” and “the” are intended to include plural alternatives, e.g., at least one. The terms “including”, “with”, and “having”, as used herein, are defined as comprising (i.e., open language), unless specified otherwise.


When Applicant discloses or claims a range of any type, Applicant's intent is to disclose or claim individually each possible number that such a range could reasonably encompass, including end points of the range as well as any sub-ranges and combinations of sub-ranges encompassed therein, unless otherwise specified. Numerical end points of ranges disclosed herein are approximate, unless excluded by proviso.


Values, ranges, or features may be expressed herein as “about”, from “about” one particular value, and/or to “about” another particular value. When such values, or ranges are expressed, other embodiments disclosed include the specific value recited, from the one particular value, and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that there are a number of values disclosed therein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. In another aspect, use of the term “about” means ±20% of the stated value, ±15% of the stated value, ±10% of the stated value, ±5% of the stated value, ±3% of the stated value, or ±1% of the stated value.


Although embodiments described herein are made with reference to example embodiments, it should be appreciated by those skilled in the art that various modifications are well within the scope of this disclosure. Those skilled in the art will appreciate that the example embodiments described herein are not limited to any specifically discussed application and that the embodiments described herein are illustrative and not restrictive. From the description of the example embodiments, equivalents of the elements shown therein will suggest themselves to those skilled in the art, and ways of constructing other embodiments using the present disclosure will suggest themselves to practitioners of the art. Therefore, the scope of the example embodiments is not limited herein.

Claims
  • 1. A method of manufacturing a watercraft, the method comprising: cutting a port hull section from a sheet of aluminum, the port hull section comprising a port corner extension extending from a posterior of the port hull section;cutting a starboard hull section from a sheet of aluminum, the starboard hull section comprising a starboard corner extension extending from a posterior of the starboard hull extension;joining the port hull section and the starboard hull section along a hull midline to form a hull;joining a lower transom to a lower posterior edge of the hull;bending and joining the port corner extension to a port side of a transom assembly;bending and joining the starboard corner extension to a starboard side of the transom assembly; andattaching an interior liner and deck to the hull and transom assembly.
  • 2. The method of claim 1, wherein bending the port corner extension forms a rounded port corner at a stern of the watercraft, and wherein bending the starboard corner extension forms a rounded starboard corner at the stern of the watercraft.
  • 3. The method of claim 2, further comprising: attaching a curved port rail to the rounded port corner; andattaching a curved starboard rail to the rounded starboard corner.
  • 4. The method of claim 3, wherein the curved port rail and the curved starboard rail each comprise a rigid extrusion and a resilient component.
  • 5. The method of claim 1, wherein the transom assembly comprises an upper transom, a transom step, the lower transom, a port transom wing, and a starboard transom wing.
  • 6. The method of claim 5, wherein the port corner extension comprises a port extension top edge, a port extension bottom edge, and a port extension distal edge, andwherein the starboard corner extension comprises a starboard extension top edge, a starboard extension bottom edge, and a starboard extension distal edge.
  • 7. The method of claim 5, wherein joining the port corner extension to a port side of a transom assembly comprises: joining a port extension bottom edge to the port transom wing; andjoining a port extension distal edge to the upper transom.
  • 8. The method of claim 5, wherein joining the starboard corner extension to a starboard side of a transom assembly comprises: joining a starboard extension bottom edge to the starboard transom wing; andjoining a starboard extension distal edge to the upper transom.
  • 9. The method of claim 6, wherein the deck extends to the port extension top edge and the starboard extension top edge.
  • 10. The method of claim 1, further comprising attaching a port gunnel to the port hull section and attaching a starboard gunnel to the starboard hull section.
  • 11. An aluminum watercraft comprising: a hull comprising a port hull side wall and a starboard hull side wall;a port corner extension extending from a posterior of the port hull side wall;a starboard corner extension extending from a posterior of the starboard hull side wall;a transom assembly attached to a hull lower posterior edge of the hull; anda deck attached to the hull,wherein the port corner extension is bent to attach to a port side of the transom assembly and to form a rounded port corner, andwherein the starboard corner extension is bent to attach to a starboard side of the transom assembly and to form a rounded starboard corner.
  • 12. The aluminum watercraft of claim 11, further comprising: a curved port rail attached to the rounded port corner; anda curved starboard rail attached to the rounded starboard corner.
  • 13. The aluminum watercraft of claim 12, wherein the curved port rail and the curved starboard rail each comprise a rigid extrusion and a resilient component.
  • 14. The aluminum watercraft of claim 13, wherein the transom assembly comprises an upper transom, a transom step, a lower transom, a port transom wing, and a starboard transom wing.
  • 15. The aluminum watercraft of claim 14, wherein the transom assembly attaches to the hull lower posterior edge of the hull along the lower transom.
  • 16. The aluminum watercraft of claim 14, wherein the port corner extension comprises a port extension top edge, a port extension bottom edge, and a port extension distal edge, andwherein the starboard corner extension comprises a starboard extension top edge, a starboard extension bottom edge, and a starboard extension distal edge.
  • 17. The aluminum watercraft of claim 14, wherein a port extension bottom edge attaches to the port transom wing; andwherein a starboard extension bottom edge attaches to the starboard transom wing.
  • 18. The aluminum watercraft of claim 14, wherein a port extension distal edge attaches to a port side of the upper transom; andwherein a starboard extension distal edge attaches to a starboard side of the upper transom.
  • 19. The aluminum watercraft of claim 16, wherein the deck extends to the port extension top edge and the starboard extension top edge.
  • 20. The aluminum watercraft of claim 11, further comprising: a port gunnel attached to the port hull side wall; anda starboard gunnel attached to the starboard hull side wall.