---
title: Build a 'Flipflopi' boat
slug: build-a-flipflopi-boat
description: The Flipflopi is a sailing boat constructed from recycled plastic and flip-flops gathered in Kenya. 

Here, we share its construction process and insights gained.
tags: ["product","research","extrusion"]
category: Guides
difficulty: Very Hard
time: 1+ months
location: Lamu, Kenya
---
import { Image } from 'astro:assets'
# Build a 'Flipflopi' boat
<Image src={import('./flipflopi-sailing-front-2.jpg')} alt="Build a 'Flipflopi' boat" />
The Flipflopi is a sailing boat constructed from recycled plastic and flip-flops gathered in Kenya. 

Here, we share its construction process and insights gained.

User Location: Lamu, Kenya
## Steps
### Step 1: Intro

This boat is a prototype, the first of its kind. The methods used were experimental and imperfect. Use this as a learning tool and for inspiration.


<Image src={import('./flipflopi-howto-step1.jpg')} alt="flipflopi-howto-step1.jpg" />

### Step 2: Get a boatbuilder

## How to Build a Boat with Alternative Materials

We began by collaborating with a local boat builder, Ali Skanda from Lamu, who was open to using unconventional materials. He and his team applied their expertise to this new challenge.

It is advisable to partner with experienced boat builders to focus on integrating new materials into existing processes without the added complexity of mastering boat construction.


<Image src={import('./flipflopi-howto-step2-1.JPG')} alt="flipflopi-howto-step2-1.JPG" />


<Image src={import('./flipflopi-howto-step2-2.JPG')} alt="flipflopi-howto-step2-2.JPG" />


<Image src={import('./flipflopi-howto-step2-3.jpg')} alt="flipflopi-howto-step2-3.jpg" />

### Step 3: Make a plan

We collaborated with Ali Skanda to design a boat and outline the necessary components and joineries.

The aim is to construct a boat large enough to convey the message against single-use plastic and plastic pollution globally.

Below are sketches providing an overview of the parts.


<Image src={import('./BoatBuild-1.jpg')} alt="BoatBuild-1.jpg" />


<Image src={import('./flipflopi-howto-step3-1.jpg')} alt="flipflopi-howto-step3-1.jpg" />


<Image src={import('./flipflopi-howto-step3-2.jpg')} alt="flipflopi-howto-step3-2.jpg" />

### Step 4: Test manufacturers & materials

In our effort to produce everything locally in Kenya, a significant challenge was establishing collaborations with manufacturers capable of delivering quality materials consistently.

Initially, manufacturers mixed different plastics or added substances like sawdust or sand as stiffeners. We succeeded in having them work with a single type of plastic without additives. An essential step in this process involved obtaining material samples and testing the joinery for boat construction.

Starting with samples can help save time and reduce costs before ordering larger quantities of materials.


<Image src={import('./flipflopi-howto-step4-2.JPG')} alt="flipflopi-howto-step4-2.JPG" />


<Image src={import('./flipflopi-howto-step4-3.jpg')} alt="flipflopi-howto-step4-3.jpg" />


<Image src={import('./flipflopi-howto-step4-4.jpg')} alt="flipflopi-howto-step4-4.jpg" />

### Step 5: Start building

Having established the procedures, we began manufacturing components for a 79-foot (24-meter) boat. The parts were substantial. 

Although the quality was quite basic, it demonstrated feasibility. Given the novelty and significant investment involved, we opted to build a smaller 33-foot (10-meter) prototype first.

Next, we will detail how we created the Flipflopi Dogo ("dogo" means "small" in Kiswahili).


<Image src={import('./flipflopi-howto-step5-2.jpg')} alt="flipflopi-howto-step5-2.jpg" />


<Image src={import('./IMG_6381.JPG')} alt="IMG_6381.JPG" />

### Step 6: The big parts

### Overview of Production Process

The production of major components like the keel and ribs posed significant challenges. We utilized available resources, acknowledging potential areas for improvement. 

We worked with a plastic manufacturer in Malindi known for producing fencing posts and tiles. 

Below is an overview of their process. We created over 30 metal molds for various boat parts, using HDPE, a commonly collected material. 

Sam and his team were instrumental in exploring different processes and materials.


<Image src={import('./FF-boatbuilding-process-1.png')} alt="FF-boatbuilding-process-1.png" />


<Image src={import('./flipflopi-howto-step5.jpg')} alt="flipflopi-howto-step5.jpg" />


<Image src={import('./IMG_0902.JPG')} alt="IMG_0902.JPG" />

### Step 7: The planks

For the planks, we collaborated with manufacturers in Nairobi who also produce fencing posts and other construction materials. It is common to mix sawdust into the material to enhance stiffness and reduce costs, though this mixture can compromise durability. After several attempts, we succeeded in producing planks made entirely from recycled plastic. These planks were crafted using professional, industrial machines, but can also be made using the Extrusion Pro machine.


<Image src={import('./flipflopi-dogo-42-.jpg')} alt="flipflopi-dogo-42-.jpg" />


<Image src={import('./flipflopi-howto-step6-1-.jpg')} alt="flipflopi-howto-step6-1-.jpg" />

### Step 8: The flip-flop sheets

Certainly. Here is the revised text:

---

Forty percent of the waste collected on beaches consisted of flip-flops, inspiring the project's name and their inclusion in the boat's design.

The entire boat was covered with sheets of flip-flops, providing a colorful appearance and an additional protective layer resembling a large yoga mat.

These sheets were crafted by local artist James, who cuts the flip-flops into pieces, glues them, and sands them into even sheets.


<Image src={import('./flipflopi_howto-flipflops-1.jpg')} alt="flipflopi howto-flipflops-1.jpg" />


<Image src={import('./flipflopi_howto-flipflops-2.jpg')} alt="flipflopi howto-flipflops-2.jpg" />


<Image src={import('./IMG_6261.JPG')} alt="IMG_6261.JPG" />

### Step 9: The boat build

## How to Build the Boat

Begin with constructing the keel, ribs, and connection parts, followed by forming the hull with extruded planks, and conclude with the Flipflop sheets.

The boatbuilders adhered to traditional methods, using fundamental tools, where screws were inserted with a hand drill and screwdriver.

This hands-on expertise requires a skilled boatbuilder.


<Image src={import('./flipflopi-dogo-36.JPG')} alt="flipflopi-dogo-36.JPG" />


<Image src={import('./flipflopi-dogo-27_copy.jpg')} alt="flipflopi-dogo-27 copy.jpg" />


<Image src={import('./flipflopi-flipflopis.jpg')} alt="flipflopi-flipflopis.jpg" />

### Step 10: Sail and inspire!

The next step involved adding parts from other sailing boats, such as the mast, boom, sail, and ropes. With these additions, the boat was ready for its intended purpose: sailing. 

On our maiden voyage, the boat successfully sailed over 310 miles (500 km) from northern Kenya to Zanzibar, safely transporting passengers and capturing interest along the route.

**Important:** Ensure your boat is seaworthy. You are responsible for the safety of yourself and your passengers.


<Image src={import('./FF-boatbuilding-process-7.jpg')} alt="FF-boatbuilding-process-7.jpg" />


<Image src={import('./flipflopi-sailing-3_copy.jpg')} alt="flipflopi-sailing-3 copy.jpg" />


<Image src={import('./9-phase_1-Diani-.jpg')} alt="9-phase 1-Diani-.jpg" />

### Step 11: Things we learned

It was a significant endeavor with considerable learning, resulting in a functional boat. However, the process had room for improvement.

During this time, we conducted additional tests and analyzed material properties. A report is available here: [Material Analysis Report](tinyurl.com/flipflopi-material-analysis).

The document shared in Step 1 contains further details.


<Image src={import('./Screenshot_2020-10-07_at_19.08.43.png')} alt="Screenshot 2020-10-07 at 19.08.43.png" />

### Step 12: Join us! ⛵️ 

### Project Update

We have successfully engaged numerous individuals worldwide with our expedition and its narrative, effectively fostering beneficial change.

Our next step is to construct a larger vessel capable of navigating greater distances and reaching a broader audience. This ambitious project presents several challenges, but as Ali Skanda notes, "Kila kitu inawezekana" – everything is possible.

For inquiries or to support our endeavors, please contact theflipflopi@gmail.com or consider supporting us at [patreon.com/theflipflopi](https://www.patreon.com/theflipflopi).

If you create a similar vessel, we encourage you to share your achievements with us.


<Image src={import('./kubwa-next.jpg')} alt="kubwa-next.jpg" />