Repairing An Aluminum Hull
Your boat takes you on all sorts of adventures, work trips, and relaxing voyages, so it’s only fair for you to take care of it in return. Aluminum hulls are resilient, but even the best boats need maintenance every so often. We here at L&M Marine know a thing or two about caring for your craft, so we’ve put together some tips for repairing an aluminum hull. If you want to know more, or you’re on the market for a new aluminum boat, contact our store in Stapleton, Alabama, today!
Supplies
For this process, you’ll need:
- Three saw horses
- Acetone
- Rags
- Particle mask & gloves
- A body hammer
- A hand anvil
- Epoxy
- Aluminum strips and scrap metal, thin gauge
- A drill motor
- A grinding cone bit
- 220-grit sandpaper
- A propane torch
- A wire brush
- An HTS-2000 brazing rod
- A flat file
Ideally, you’ll also have an assistant to help you out, since a few of these steps will require more than two hands.
Setup
Get your boat to a nice sheltered, dry area to work on it and set it up on the three saw horses, which should be set up in a triangular configuration. Put on your gloves and goggles and clean the damaged area using the acetone and rags until it’s clear of all growth, debris, and stains.
Hammering
If the hull is dented, you’ll need to get it back into shape before fixing further damage. Have your assistant hold the hand anvil against the outside of the dented area while you hammer lightly at the dent from the inside, tapping and straightening the bent aluminum until it’s close to its original shape.
Prepping For Sealing
If there’s a hole or crack, figure out its approximate dimensions and use epoxy to fix some of the scrap metal to the outside of the puncture. This will create a stable place for the brazen rod material to settle.
Clean The Puncture
If your hull is cracked, use your drill and cone bit to cut the crack into a V-shaped channel, with the small end of the V being the crack itself. If there’s a simple hole, grind just enough away so the brazen rod material has something to bind to. Sand it down with the 220-grit.
Fill In
Heat up the area around the puncture with your propane torch, then scrape it with the wire brush to rough up the surface, which will help the brazen rod material bind to it. Hold the heat steady on the puncture while applying the tip of the HTS-2000 brazing rod over the sides of the puncture, allowing it to melt and flow into the gap. Make sure the melted material overlaps itself and fills in the gap entirely. As it cools, use the wire brush to scrape away slag and residue.
Finish Up
Once it’s cooled entirely, use the flat file to remove excess brazen rod material that extends past the aluminum panel, getting it even without digging into the brazen weld. Remove the scrap aluminum from the outside of your hull, and you’re all set!
On the other hand, if you don’t have the time, materials, or confidence needed to perform these repairs yourself, contact us at L&M Marine! Our maintenance technicians are ready and waiting to get your boat back in one piece and on the water. We proudly serve the people of Mobile, Alabama, and Pensacola, Florida—let us serve you today!