After several weeks ( well more than several, actually) of working in the keel  and tank area, I finally decided  it was time to begin doing some plating!  I  had built a full scale mockup in wood of the keel structure, which I took to the plate rolling factory, along with the precut keel sides (thank you, Alumar) which were 3/8" (10mm) thick 44" wide by 14' long . These we rolled into shape, paying especial care at the leading edge, as this is a conical bend and the edges need to fair into the leading edge pipe for a smooth flow. 
After a test fit of the port side plate on the boat, which looked pretty good)I decided to cut soem small notches in the frames, right where the keel floors turn down ( up)These shallow notches served to hold the root edge tight, while I was able to clamp across the 3/4" (20mm) keel sole and draw the plate tight to the slightly curved keel floors. The leading edge fit perfectly! ( at least on the port side!) There's lots more detail of the building of Odyssey, a Dix 43Pilot House cutter, at http://www.odysseyyachts.com

Full size wood mockup/ pattern


Sometimes it pays to hire professionals


the forklift needed an extension to get high enough


Just a nudge was needed to seat the keel root into the notches

 
The leading edge is looking nice and straight!





 

In June 2009 we received 10,000 lbs of cut aluminum plate and extrusions for our Dix 43 Pilot House. Now it's November 09 and the frames have been set up and we are rolling the stringers. I have a complete descriptive blog at my website www.odysseyyachts.com.  One small step at a time, enjoying (almost) every minute.Cheers ,Brian