Flipping An Aluminum Boat: A Step-By-Step Guide

Aluminum boats are a popular choice for fishing and family outings. However, they are also known for their tendency to bounce and pound, especially in choppy waters. While some owners opt for adding weight to the bow or using trim tabs to reduce this issue, others explore sealing their aluminum boat hulls to minimize leaks and create a slicker surface. This can be a challenging task, especially if the boat cannot be flipped over due to engine restraints. Various products and techniques, such as Gluvit, Gator Glide, and epoxy paint, are recommended by boat enthusiasts to address leaks and enhance the boat's performance.

Sealing an aluminium boat hull without flipping it

Step 1: Prepare the Boat

Before you begin sealing, ensure that the boat is securely placed on 4x4 cradles or blocks and jacks. This will provide a stable base for you to work on. It is recommended to have at least two people to help with this process, as safety is a priority.

Step 2: Seal the Rivets

Inspect the boat for any leaks, especially around the rivets. To seal the rivets, use a product like 3M 5200. Apply it generously around the rivet heads on the bottom of the hull. This will help create a watertight seal and prevent any leaks. Allow the sealer to dry completely before moving on to the next step.

Step 3: Apply a Protective Coating

Once the rivets are sealed, it's time to coat the entire bottom of the boat with a protective layer. There are a few products that can be applied without flipping the boat, such as Wetlander or Gator Glide. These coatings will not only seal minor leaks but also provide a slick surface, improving the boat's performance and making it easier to load and unload.

Step 4: Consider a Two-Part Epoxy Paint

If you're looking for a more durable solution, consider using a two-part epoxy paint. This can be rolled on from under the boat, but make sure to follow the manufacturer's instructions carefully. Epoxy paint provides a strong and flexible coating that can withstand the elements.

Step 5: Alternative Options

If you're unable to access the inside of the hull due to flooring or other obstacles, there are alternative options. One suggestion is to use a product called Gluvit, which is designed to seal leaks from the inside of the hull. Another option is to take your boat to a Line-X dealer and have them apply a marine-grade coating, such as Line X XS350.

Step 6: Safety Considerations

Always work in a well-ventilated area when applying sealants and coatings. Wear protective gear, including gloves, eye protection, and a respirator. Ensure that any flammable materials are kept away from the work area, and follow all safety instructions on the products you are using.

Using epoxy paint to seal an aluminium boat hull

To seal an aluminium boat hull using epoxy paint, follow the steps below:

Firstly, ensure that the aluminium surface is clean, bright, shiny, and free of oxidation and surface contamination. This is crucial, as it ensures that the paint will adhere properly to the hull. You can use a product like TotalBoat Aluminum Boat Etch Wash to clean, condition, brighten, and etch the surface.

Next, you'll need to choose the right epoxy paint for the job. A two-part, high-build epoxy barrier coat, such as TotalBoat Aluminum Boat Barrier Coat, is ideal for providing exceptional corrosion protection on aluminium boats. This type of epoxy paint can be applied by brush, roller, or spray equipment, making it a versatile option. Mix the epoxy paint according to the manufacturer's instructions, typically following a simple 3:1 mix ratio of base to curing agent.

Once the epoxy paint is mixed, you can begin applying it to the hull. Depending on the size of your boat and the application method, you may need multiple people to help with this process. Be sure to follow the recommended dry times between coats, as this will ensure proper adhesion and a smooth finish. For TotalBoat Aluminum Boat Barrier Coat, the dry time for additional coats is 2 hours to 60 days at 90ºF or 3 hours to 60 days at 70ºF.

If you are unable to flip the boat over, you can still apply the epoxy paint from underneath. This may require some creative problem-solving, such as using a hoist or jack system to safely raise the boat and provide access to the hull. Always make sure to have enough help when handling the boat to avoid any accidents or injuries.

Finally, allow the epoxy paint to cure completely before launching the boat. For TotalBoat Aluminum Boat Barrier Coat, the dry time to launch is a minimum of 12 hours at 90ºF, 24 hours at 70ºF, or 5 days at 50ºF.

Fixing leaks in an aluminium boat

Step 1: Identify the Source of the Leak

Before you begin the repair process, it is crucial to identify the source of the leak. Leaks in aluminium boats can occur due to various reasons, such as pinhole leaks, damaged rivets, or cracks in the hull. Carefully inspect your boat to determine the exact location and cause of the leak.

Step 2: Gather the Necessary Materials and Tools

To repair leaks in an aluminium boat, you will need a few essential materials and tools. These may include items such as marine epoxy, acetone, sandpaper, putty knives, propane torches, wire brushes, and aluminium brazing sticks or aluminium welding rods. Having all the necessary supplies ready will make the repair process more efficient.

Step 3: Clean and Prepare the Surface

Before applying any repair material, it is important to clean and prepare the surface around the leak. Use acetone to wipe down the area, ensuring that it is free from grease, oil, or dirt. Once the area is clean, use sandpaper to roughen the surface, creating a suitable base for the repair material to adhere to.

Step 4: Apply the Repair Material

There are several repair materials available for fixing leaks in aluminium boats. One commonly used method is to use marine epoxy. Combine the epoxy resin and hardener in the specified ratio, and use a putty knife to apply it over the leak. Ensure you follow the manufacturer's instructions for the best results. Alternatively, you can use specialised products like JB Water Weld, which is a putty-like epoxy that can be kneaded and applied directly to the leak.

If you have experience with welding, you can opt for aluminium welding rods or brazing sticks. These require the use of a propane torch to melt and apply the repair material over the leak. This method creates a strong and permanent bond but may require more skill and expertise.

Step 5: Allow Adequate Curing Time

After applying the repair material, it is crucial to allow sufficient time for it to cure and harden. The curing time can vary depending on the product used, environmental conditions, and the size of the repair. Always refer to the manufacturer's instructions for specific curing times.

Step 6: Test the Repair

Once the repair material has cured, thoroughly inspect and test the repaired area. Fill the boat with water and check for any signs of ongoing leaks. If necessary, apply additional repair material and repeat the curing process until the leak is completely sealed.

Step 7: Consider Additional Protection

As a final step, you may want to consider applying a protective coating over the repaired area. This can provide an extra layer of defence against leaks and help extend the lifespan of your boat. Products like Flex Seal or Flex Paste can be used to create a rubbery finish that enhances the seal.

Remember, safety should always be a priority when working on boat repairs. Wear appropriate protective gear, including gloves, eye protection, and a respirator when working with chemicals or welding materials. By following these comprehensive steps, you can effectively repair leaks in your aluminium boat, ensuring it remains seaworthy and safe for your future adventures.

Reducing bouncing/pounding in an aluminium boat

Reducing the bouncing or "porpoising" in an aluminium boat is important for both comfort and safety. Here are some ways to minimise this issue:

Firstly, slowing down the boat can be effective, as porpoising often begins when the boat accelerates and the hull is raised from the water. Reducing speed keeps more of the hull in the water, providing better support.

Trimming the motor down can also help to address this issue. Adjusting the trim of the motor changes the axis of power applied to the boat, keeping the bow from rising too high. This can be complemented by moving passengers or cargo towards the bow, as this helps to hold the front of the boat down.

Additionally, mounting trim tabs on the stern and trimming them downward during acceleration can be beneficial. This adjustment changes the speed at which the bow leaves the water, reducing the bouncing effect. For outboard motors, adding a "wing" or hydrofoil to the top of the anti-cavitation plate can be an effective alternative to trim tabs, as it acts like a fixed trim tab.

Finally, it is always important to wear a personal flotation device when in an aluminium boat, especially in smaller vessels that are more prone to porpoising.

Rehauling/flipping an aluminium boat

Step 1: Find the Right Boat

Look for a boat within your budget that has potential for improvement. Consider the hull condition, brand, and style. Aim for welded boats rather than riveted ones, and inspect closely for corrosion. Recommended brands include Klamath, Valco, Gregor, Bayrunner, and Seahawk.

Step 2: Assess the Boat's Condition

Before beginning any work, carefully inspect the boat for any issues. Look for corrosion, leaks, and the condition of the benches and flooring. Take note of any necessary repairs or replacements.

Step 3: Create a Plan

Based on your assessment, create a plan for the rehaul. Decide on the scope of work, including any repairs, painting, seating arrangements, and engine installation. Determine the order of tasks and create a timeline to help stay organised and on track.

Step 4: Gather Tools and Materials

Ensure you have all the necessary tools and materials before beginning work. This may include items such as paintbrushes, rollers, epoxy paint, rivets, seals, and any other specific items required for your project.

Step 5: Prepare the Work Area

Choose a suitable work area that provides enough space and access to flip the boat. Ensure you have the necessary equipment to safely flip the boat, such as blocks, jacks, braces, and a hoist if needed. Have a helper or two to assist with the flip for added safety.

Step 6: Flip the Boat

With the necessary preparations in place, carefully flip the boat over. Ensure the boat is securely supported and blocked to prevent any accidents. Now you can access the underside of the hull for repairs, sealing, or painting.

Step 7: Seal and Paint the Hull

If sealing the hull, use a product like 3M 5200 to seal around rivet heads, followed by a coating of Wetlander or a similar product. For painting, use a two-part epoxy paint applied with rollers or brushes. Ensure proper ventilation during the sealing and painting process.

Step 8: Reinstall Fixtures and Accessories

Once the hull work is complete and the paint is dry, carefully flip the boat back over. Reinstall any fixtures, accessories, and seating arrangements according to your plan. Ensure that all connections are secure and properly sealed.

Step 9: Final Touches

With the major work complete, add any final touches, such as installing a motor or making aesthetic improvements. Test all systems and ensure the boat is seaworthy before taking it out on the water.

Step 10: Enjoy Your Refurbished Boat!

Take your refurbished aluminium boat out for a spin and enjoy the fruits of your labour! Remember to maintain and care for your boat regularly to keep it in good condition.

Frequently asked questions