Aluminum boat repair

[Ross]

I was given a 12 foot aluminum boat, complete with a bale spear hole (2 actually) I've cut out the twisted metal and formed an aluminum patch to cover the first hole. I could get it welded, but I know there are various types of aluminum, I'm not sure if it matters that both be the same or not. I could pop rivet the patch on with a good grade of marine sealant between and around the patch, inside and out. This would be faster of course. I'm a little worried the weld will be brittle. Mostly because I'm not much of a swimmer. How would you fix it?

[Gideon]

There are repair kits available and you should keep a couple in different sizes if planning on being out a lot. Welding should be very safe if done by a competant and experienced welder using the proper type welder. I would not be afraid to drill small holes around the hole and patch it using Silicone Sealant, Aluminum plates, and Aluminum bolts. Be careful to use Aluminum or stainless screws. You may get "bimetal corrosion" with regular steel bolts. I know Copper and Aluminum "do not mix" well. wc

[Ross]

The pop rivets I'm thinking of are aluminum.......... with a steel core which will rust out eventually. Screws would protrude in, although I could cap them with silicone. Hadn't considered bolts, there's a terrific bolt supply store close by too. "Pretty" isn't a serious factor but safe is. I would prefer to hand it off for welding, a buddy of mine is a compitant welder, and he has a TIG machine (so do I but mine needs fixing) I kind of hate to bother him with it and it'd be a couple of weeks before its done.

[Bearfootfarm]

If youre not concerned with appearance, I'd suggest the double patch and http://www.marinetex.com/

If you measure CAREFULLY you could use roundhead bolts and "acorn nuts" that would give you a rounded surface on both sides. I would NOT use silicone if the hole is below the waterline. After the patching material has set up, go back over the outer edges with more Marinetex and "feather" them evenly with the hull to avoid snagging on the patch edges.

[agmantoo]

Aluminum patch pop riveted in place and finished with Marine Tex

[Ross]

Never heard of it, I hope it's available locally. There are several marina's around and a few good hardware stores. Thanks. My friend is goign to stop in after work and check it out. The one hole is a torn rectangle about 8x11 inches so it's substantial and below the water line. I have the aluminum patch formed to over lap by 2 inches. The second hole is more or a tear/puncture on the transom. That one looks easier to fix.

[WayneR]

HF sells repair rods that will work with aluminum, pot metal, etc.

Just need to sand mating surfaces with CLEAN sandpaper. Do the same with the rod material. Uses propane torch. Wet the mating surfaces first then join them together. Permanent . Works.

Same stuff they advertise on TV under the alumaloy name