Finding Leaks In Your Welded Aluminum Boat: A Comprehensive Guide

If you're looking to find leaks in a welded aluminium boat, there are a few methods you can try. Firstly, try filling the boat with water and inspecting the hull for any signs of leakage. If the leak is large enough, it should be easy to spot. You could also add food colouring to the water to make it more visible. If you suspect the leak is coming from the drain plug seal or the livewell pumps, it may be harder to identify the exact source of the problem. In that case, it's best to consult with a professional or an experienced friend to avoid making the issue worse.

If you're unable to find the leak, you could try taking the boat to a TIG welder to get an estimate for repairs. Welding a riveted boat can be risky as it may cause leaks where there weren't any before, so make sure the welder is skilled and cleans the boat properly before beginning any work.

There are also a number of products available to fix small cracks and holes in your boat, such as Flex Seal, Marine Adhesive Sealant, and various epoxy solutions. When using epoxy, remember to use a heat gun to melt it and force it through the gaps. You can also use a liner coating for a pickup truck's bed as an inexpensive way to add extra protection to the inside of your boat.

Remember to always exercise patience and let the boat dry thoroughly before taking it back out on the water.

Inspect the hull for leaks

Inspecting the hull for leaks is a challenging but crucial task in maintaining your aluminium boat. Here are some detailed steps to guide you through the process:

Step 1: Place the Boat on Land

Take your boat out of the water and place it on a trailer or dry land. This step is essential to access the hull and conduct a thorough inspection. Ensure that the boat is securely positioned and stabilised to prevent any accidental movements or instability during the inspection process.

Step 2: Fill the Boat with Water

Start by partially filling the boat with water. This will help you identify any leaks or puncture points. Observe the hull for any signs of water escaping. If you notice immediate leaks, proceed to identify and mark the affected areas. However, if no leaks are visible, wait for a few hours to allow potential slower leaks to develop.

Step 3: Use Food Colouring (Optional)

If you're having difficulty spotting leaks, adding a few drops of food colouring to the water can make them more visible. This technique can help you identify even small leaks that may otherwise be challenging to detect. Simply add a few drops of food colouring to the water and stir it gently to distribute the colour evenly.

Step 4: Inspect Common Leakage Spots

While inspecting the hull, pay close attention to common leakage spots, such as transducer screw holes and rivets. Livewell pumps on the transom can also be a source of leaks, and it may be challenging to identify the exact location of the leak in this area. Remember to start your inspection with the easiest and cheapest causes first before moving on to more significant potential issues.

Step 5: Mark and Document Leak Locations

As you identify leaks, use a marker or some other means to circle or mark the affected areas. This will help you pinpoint the exact locations that require repair or sealing. Additionally, consider taking photos or making notes of the leak locations for future reference.

Step 6: Consult a Professional (If Needed)

If you encounter extensive leaks or structural issues beyond your expertise, don't hesitate to consult a professional boat repair specialist. They can provide guidance and ensure that the repairs are done correctly and safely. Remember, it's always better to seek professional help than to risk making costly mistakes or causing further damage to your boat.

Check the drain plug seal

If you suspect that your welded aluminium boat is leaking from the drain plug seal, there are several steps you can take to check and address the issue.

First, inspect the drain plug and its housing for any signs of damage or wear. Look for cracks, corrosion, or other abnormalities that could indicate a leak. If the plug is old, it may be worth replacing it as a precautionary measure.

If the plug appears to be in good condition, try tightening it to ensure a secure fit. If it is a threaded plug, use Teflon tape or pipe dope from the plumbing section of a hardware store to create a tighter seal.

You can also apply a sealant to the drain plug and its housing. Clean the area thoroughly, removing any old grease or silicone, and then apply a marine-grade sealant or silicone. Allow it to dry completely before testing.

If you suspect the leak is coming from the o-ring on the drain plug, try replacing the o-ring with a new one. O-rings can become worn or damaged over time, causing leaks.

If you are still unable to locate the source of the leak, try filling the boat with water and observing if it leaks from the drain plug area. You can also add food colouring to the water to make the leak more visible.

Remember to consult a professional if you are unsure about any repair work or if the problem persists.

Identify if the livewell pumps are the source

Livewell pumps can be a source of leaks in your welded aluminium boat. They are particularly hard to spot on the transom because it is difficult to identify where the water is coming from.

To identify if the livewell pumps are the source of the leak, you can try the following:

• Inspect the livewell pumps and hoses for any signs of damage or leaks. Look for any cracks, holes, or loose connections.
• Plug the intake nipple for the livewell water and run the boat. If the boat still takes on water, it could indicate a problem with the livewell pumps or hoses.
• Try running the boat without using the livewell pump. If the boat does not take on water, it suggests that the livewell pump or its hoses may be the source of the leak.
• Check the overflow outlets of the livewell. Plug each outlet one at a time and observe if water is still coming into the boat. If you identify a particular outlet that is causing the leak, it could indicate a problem with the corresponding hose or connection.
• Use a garden hose to run water into the livewell intake at the transom. If water enters the boat, it could indicate a problem with the livewell pump or its connection.
• Consult with a professional or experienced friend. They may have specialised knowledge or tools to help identify and fix the leak.

Look for leaks in the transducer screw holes

Leaks in the transducer screw holes are one of the most common causes of leakage in aluminium boats. If you are looking for leaks in the transducer screw holes, the first step is to identify the location of the transducer. The transducer is usually bolted or screwed onto the transom.

If you are removing an old transducer, you can simply reinstall the screws with some marine sealant on the threads. If you are unable to access the inside of the hull, you can use self-tapping screws with silicone. Alternatively, you can use a rivet gun to replace the screws with closed-end rivets, which will not let water through.

If you are installing a new transducer that does not match up with the holes on the old bracket, you can seal the old holes with a variety of products. One option is to use a mapp gas torch and brazing rods to weld the holes shut. However, this method can be difficult and may result in larger holes if not done correctly. Another option is to fill the holes with marine caulk or silicone. You can also use a product called JB Weld, which is a type of marine epoxy. If you want to be able to remove the transducer in the future, you can use a product called 3M 5200, which dries rigidly and will need to be scraped or sanded off.

If you are installing a new transducer bracket, you can use a piece of polymer or UHMW cutting board as a mounting plate. You can attach the cutting board to the transom with screws and silicone or epoxy. This will provide a flat, sturdy surface to mount your new transducer.

Once you have identified and addressed any leaks in the transducer screw holes, be sure to let the boat dry thoroughly before taking it back out on the water.

Re-rivet the boat

Re-riveting an aluminium boat can be a challenging task, but it is possible to do it yourself with the right tools and knowledge. Here is a step-by-step guide to help you through the process:

Prepare the Boat and Gather Your Tools:

• Park your boat on dry land and ensure it is stable and secure.
• Gather all the necessary tools and materials, including a rivet gun, a power drill, a screwdriver, closed-in rivets, rivet burrs or washers, a marine adhesive sealant, and personal protective equipment (PPE) such as gloves and eye protection.

Identify the Leaky Rivets:

• Inspect the hull of the boat for any visible signs of leakage.
• If the leak is not immediately apparent, fill the boat with water and wait a few hours. You can also add food colouring to the water to make the leak more visible.
• Once you have identified the leaky rivets, mark them with a marker or tape so you know which ones to replace.

Drill Out the Old Rivets:

• Using a power drill, carefully drill into the centre of each old rivet.
• Use a screwdriver to punch through and remove the old rivets. Ensure you only drill out one rivet at a time to maintain the alignment of the boat's structure.

Prepare the New Rivets:

• Order closed-in rivets and rivet burrs or washers online or from a hardware store. Ensure you get the correct size and type of rivets for your boat.
• Apply a through-hull marine adhesive sealant to the new rivets. This will help create a watertight seal.

Install the New Rivets:

• Place the new rivet into the rivet gun.
• Position the rivet in the drilled-out hole and set the burr or washer on the inside of the boat for reinforcement.
• Use the rivet gun to punch in the new rivet. Be careful not to over-hammer, as this can crack the rivet.
• Wipe off any excess sealant with a clean cloth.

Test for Leaks:

• Once you have replaced all the identified leaky rivets, fill the boat with water again to test for any remaining leaks.
• If you spot any new leaks, repeat the process and replace the rivets at the new leak locations.
• Allow the boat to dry thoroughly before taking it out on the water.

Re-riveting your aluminium boat can be a time-consuming process, but it is a cost-effective way to repair leaks and ensure the safety of your vessel. Always take your time and work carefully to achieve the best results. If you are unsure or uncomfortable with any part of the process, consult a professional boat repair specialist for assistance.

Frequently asked questions