Welding is the best method for a strong and durable repair to a damaged aluminum boat hull, while fiberglass is best for eliminating slow leaks in riveted seams. Thoroughly cleaning the repair area is crucial, and wearing a breathing apparatus when welding is important. Taking time and not rushing the repair is also key.
When repairing aluminum boats, most methods require welding or fiberglass in the area that needs repair. While both methods are acceptable in aluminum boat repair, the purpose of the repair often dictates the method used. For a durable, long lasting and strong repair to a damaged hull, welding is commonly considered the best and most appropriate method of making the repair. If the necessary repair involves simply eliminating a slow leak in a riveted seam, fiberglass is often considered the best method for repairing aluminum boats. However, if the reason for repairing an aluminum boat is to complete a restoration, then welding, grinding and polishing will give the more traditional and original looking finish once the repair is complete.
Regardless of the method used in aluminum boat repair, the most important factor is to thoroughly clean the repair area before attempting any repair work. Using a mild acid to remove any oxidation from the aluminum and sanding down the damaged area to ensure you are working with strong material is the #1 tip in aluminum boat repair. Attempting to lay fiberglass over uncleaned aluminum will result in the fiberglass peeling off the aluminum in a very short time. Welding on dirty aluminum will result in a contaminated weld that will oxidize and eat away at itself, leaving several small holes in the repair area.
The tip that can really save a repairman’s life is to wear a breathing apparatus when welding aluminum. Aluminum produces a toxic gas fume when welded, making repairing aluminum boats a very dangerous practice if proper precautions are not taken. For very thin aluminum repair, a good tip is to use a torch and weld the repair rather than solder it. The brazing process will use less heat and will not damage the surrounding metal. In some cases, welding will result in the fusion of a larger hole in the boat than originally required repair.
High on the aluminum boat repair tips list is to take your time and not rush the repair. If you hurry, a driveway repair can ruin an aluminum boat. For example, if a crack in a hull is being repaired, it is recommended to drill a small hole at each end of the crack, and then the crack can be welded closed. If this additional step of drilling the ends of the crack is not performed when repairing aluminum boats, the crack can often extend through the weld area.
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