In the heart of the Black Forest, far from the salt spray, Holger Bührle is building Hulg, a 22-meter aluminum schooner. For the past 25 years, this self-taught craftsman has devoted his life to an extraordinary project, a work that combines technical skill and ingenuity. In this first part, we take a look back at a one-of-a-kind construction site, where each stage embodies perseverance and the dream of a round-the-world voyage.
The birth of a lifelong dream
Holger Bührle is not a traditional boatbuilder. Trained as an electrician, he turned to sailing out of passion, even though he lives over 500 km from the ocean. This geographical distance has never held him back, quite the contrary. '' If I had to wait until I was at the seaside to start, I'd never have done anything he confides.
His passion for the sea goes back to his adolescence, long before his construction project. Born in the Baden region, he discovered sailing at the age of 14 on Lake Schluchsee, where he obtained his A licence. It was love at first sight. Subsequent sailing expeditions, notably with his uncle in the south of France and in Greece, reinforced his desire to make a living from this passion. He started out with dinghies, then ventured out on a Tornado, but the call of the open sea was pressing.
In 1998, he completed his first Atlantic crossing aboard the Kritter, a 25-meter two-master. This voyage marked a turning point in his career, and inspired him to design a boat capable of sailing around the world, yet durable and suitable for a small crew. Discovering the plans for hydraduo designed by naval architect Kurt Reinke, that Holger Bührle laid the foundations for his project. Inspired by these lines, he decided to adapt the design to his own ambitions.
The project began modestly in his garden, far from the sea, amidst the wooded hills of the Black Forest. This geographical remoteness, far from being a hindrance, became the symbol of a personal challenge for Holger. '' Building a boat here means turning a distant dream into a tangible reality, day after day he says.
Mistakes for training
Self-taught, he learns shipbuilding techniques by dint of research, experimentation and mistakes, which he sees as an essential part of the process. At each stage of construction, he imposes on himself the quality standards he deems necessary for the extreme conditions he wishes to face at sea. The choice of aluminum, a sturdy, lightweight material, was quickly made for its resistance to corrosion, essential for long crossings in isolated environments. '' It's not just a boat I'm building, it's a vision of freedom and self-sufficiency he explains. This dream translates into a quest for perfection that drives him to work day after day, sometimes alone, sometimes with the help of enthusiasts who come to lend him a hand.
The shell: demanding processes
The aluminum hull is the technical heart of Hulg. With its long keel design, it gives the boat good stability while limiting its draught to 2 meters. This architecture ensures good behavior under sail and facilitates beaching if necessary.
The use of high-quality marine aluminum panels, cut and welded by hand with surgical precision, reduced the boat's overall weight while ensuring perfect watertightness and optimal structural strength.
Watertight compartments integrated into the hull, used as water and fuel tanks, not only add to storage capacity but also help to balance the boat when underway.
Keel manufacture: a technical process
Holger opted for a meticulous, pragmatic approach to the manufacture of his boat's keel. The process began by soldering the mold. The keel, which was only half filled with lead, required an intermediate plate to create a reservoir at the top. Auxiliary soldering holes were added to allow fuel extraction and internal soldering. Closing the 8mm plates at the front was a challenge for Holger, requiring careful heat management to avoid keel distortion. The top edge was left with a 10 cm overhang for future adjustments. Once the mold was in place, Holger had to prepare the space under the boat to install the keel. The ground was dug and two steel beams were used as rails to slide the keel under the boat. Due to the addition of lead next to the hull, a solution had to be found to move the keel 3 meters laterally, using a technique inspired by Egyptian methods with open rollers.
The lead pour took place over two days, non-stop. The work was demanding, releasing yellow smoke that enveloped the residential area, as Holger's team poured lead in 100 kg portions, layer by layer. Each layer of lead had to cool under water, making the operation particularly delicate. After a period of cooling and regeneration, the keel was adjusted to the template. Final adjustment only took place in the final position, where the fuselage rested on two steel beams adjustable in height by means of threaded rods. This compensated for ground movements. Finally, once the keel was in place, the edge was chamfered, and four layers of welding were applied to finalize the manufacture of this crucial element of the boat.
A bridge that stands the test of time
The deck, clad in 8 mm teak, rests on a 6 mm support plate designed to limit the effects of expansion variations. For all jointing and bonding, Holger chose Sika products, in particular the levelling compound which is particularly effective in correcting the irregularities frequently observed on a metal deck. His aim was to keep the deck as uncluttered and fluid as possible, an approach illustrated by the integration of large XXL fold-out mooring cleats, unobtrusive when folded.
A rig designed for performance and durability
Featuring a 22.5-meter main mast and a 19.5-meter mizzen mast, the yacht will benefit from a large sail area. Modern, fully battened sails will be mounted on roller car systems for easy handling. Winches, jib furlers and tensioning systems will be hydraulically operated, a technical feat that brings comfort and precision in all conditions.
