Installing A T-Top On Your Aluminum Boat: A Step-By-Step Guide

Installing a T-top on an aluminium boat is a great investment and can be done as a DIY project or by a professional. T-tops are a great addition to boats as they add much-needed shade, functionality for fishing, and increase the boat's resale value. When installing a T-top, it is important to consider the type of deck and mounting hardware. For wooden decks, it is recommended to glass in extra mounting blocks, while for aluminium decks, welding on aluminium plates or tubing and using stainless steel screws can provide a stable and sturdy installation. Additionally, using marine-grade caulk can help prevent leaks. T-tops made from 6061-T6 aluminium alloy are recommended for their durability, corrosion resistance, and lightweight properties.

Welding vs screwing

When installing a T-top on an aluminium boat, there are two main methods to consider: welding or screwing. Both methods have their own advantages and can be effective ways to secure the T-top to the boat.

Welding is a process that uses high temperatures to join two pieces of metal together. In the case of installing a T-top on an aluminium boat, welding would involve using a welding machine to create a strong, permanent bond between the T-top and the boat's surface. This method is often considered to be more durable and long-lasting than screwing, as it creates a seamless joint between the two pieces of metal. Additionally, welding can be a good option if you have access to the necessary equipment and have some experience with welding techniques. However, it is important to note that welding can be more complex and time-consuming than screwing, and it may not be suitable for all types of aluminium boats.

On the other hand, screwing involves using screws and other fasteners to secure the T-top to the boat. This method is generally easier and faster than welding, making it a popular choice for DIY installations. Screwing also offers the advantage of being more flexible, as it allows for adjustments or removals in the future. Additionally, screwing does not require specialised equipment, and it can be done with basic tools and hardware. However, it is important to use the right type of screws and fasteners that are suitable for aluminium and marine environments.

When deciding between welding and screwing, it is important to consider the specific requirements of your project. If you prioritise durability and permanence, welding may be the better option. However, if you prefer a more flexible and accessible installation method, screwing might be more suitable. Additionally, factors such as the availability of equipment, your level of experience, and the specific characteristics of your boat should also be taken into account.

Ultimately, both welding and screwing can be effective ways to install a T-top on an aluminium boat. By carefully evaluating the advantages and considerations of each method, you can make an informed decision that best suits your needs and ensures a secure and stable T-top for your boat.

Reinforcing the surface

If you have a wooden deck, you can reinforce it by glassing in some extra mounting blocks onto the topsides or the underside of the deck. For an aluminium deck, you can weld on aluminium plates or tubing to provide a sturdy base for the T-top. It is recommended to use aluminium plates that are 1/4" thick or greater, and to use the largest stainless steel sheet metal screws and hardware available that will fit through the aluminium deck.

When attaching the T-top to the reinforced surface, it is important to use stainless steel hardware throughout and to apply a generous amount of 3M 5200 marine caulk to the joints to prevent leaks. Make sure to follow the manufacturer's instructions and use the correct type and amount of caulk to ensure a watertight seal.

Additionally, if your boat has a centre console with a side access door, you should be careful when choosing the design of your T-top. Some designs have a horizontal leg brace that may block the door from opening fully. One solution is to choose a design with a higher side brace and additional standoffs for stability, or you may need to remove the door hinge pins to allow the door to be removed when necessary.

Using SS hardware

When installing a T-top on an aluminium boat, it is important to use SS hardware throughout the process. This is to ensure that the mounting hardware has plenty to bite into.

If you have a wooden deck, you can use SS hardware to glass in some extra mounting blocks onto the topsides or the underside of the deck. If you have an aluminium deck, you can weld on some aluminium mounting pads and then attach the T-top using SS sheet metal screws and hardware.

When attaching the T-top to the deck, you can use SS hardware to through-bolt the tower to the deck. Make sure to use the largest SS hardware that will fit. If you are unable to through-bolt, you can also use SS self-tapping screws to attach the T-top to the mounting surface.

Additionally, when installing a T-top, it is important to apply a generous protective layer on all the threads of each bolt. This is because aluminium and stainless steel will experience galvanic corrosion when put together. Products such as Permatex or Loctite are recommended to thread lock the bolts. If you have a folding T-top, you will need to use an anti-seize lubricant with galvanic protection, such as LanoCote or Tef-Gel, on some of the bolts.

Finally, when tightening the SS bolts, be careful not to over-torque and strip the threads, as this can be disastrous and challenging to repair or replace.

Applying marine caulk

When installing a T-top on an aluminium boat, it is important to apply marine caulk to prevent leaks. Here is a step-by-step guide on how to apply marine caulk:

Surface Preparation:

Start by preparing the surface of your aluminium boat. Clean the area where you will apply the caulk by sanding it with 80-grit sandpaper. Ensure the surface is free of any dirt, dust, grease, loose paint, oils, or other contaminants. This step is crucial for achieving a strong bond and seal.

Remove Existing Caulking:

If there is any existing bead of caulking, remove it using a reefing tool, a reefing hook, or a makeshift tool. An old-fashioned can opener or a heated and bent screwdriver shaft can also be used for this purpose. This step ensures a smooth surface for the new caulk application.

Solvent Cleaning:

Use a solvent such as lacquer thinner or mineral spirits to remove any residual skin or old sealant. This step ensures a good bond and seal for the new marine caulk. Always wear protective gear and be cautious of fire hazards when working with solvents.

Masking:

Apply masking tape on both sides of the seam to be caulked, approximately 1/8 inch away from the seam. For rounded corners, overlap the tape at a right angle and then carefully cut out the radius using a utility knife and a guide, such as a jar cap. Masking may take time, but it makes cleanup easier later.

Cut the Caulking Nozzle Tip:

Examine the caulking nozzle tip and cut it at a 45-degree angle, creating an oval-shaped hole. The narrow dimension of the oval should be just slightly narrower than the width of the seam or bead you need to caulk. This ensures a precise and neat application.

Apply Caulk:

Load the marine caulk into a caulking gun. When applying the caulk, push the caulking gun instead of pulling it. Maintain a steady pace, ensuring that the speed of pushing does not exceed the rate at which the caulk is dispensed from the tip. Aim for a slight "hill" or "ball" of caulk just in front of the tip as you move along the seam.

Tooling:

After applying the caulk, you will have some time to fix or neaten the bead before it starts to skin over. Dip a gloved finger in water and swipe the bead gently to smooth it out. Wipe your fingers between swipes to maintain a clean finish. Remove the masking tape before the caulk skins over as well.

Always follow the safety instructions on the marine caulk product and wear protective gear during the application process.

Attaching to the console

Attaching the T-top to your aluminium boat's console is a crucial step in ensuring its stability and strength. Here is a detailed guide on how to go about it:

Firstly, you will need to determine the type of deck your boat has. If you have a wooden deck, you can reinforce it by glassing in mounting blocks onto the topsides or underside of the deck. For an aluminium deck, welding on aluminium mounting pads or plates is recommended. These plates should be at least 1/4" thick and can be accompanied by pieces of square tubing. This will provide a sturdy base for attaching the T-top.

When attaching the T-top to the console, it is essential to use stainless steel (SS) hardware. Make sure to select screws or bolts that are large enough to provide ample support. Apply a generous amount of 3M 5200 marine caulk to the hardware before installation to prevent leaks.

If you are unable to access the underside of the floor, you can opt for through-bolting the T-top to the deck. Alternatively, you can use screws, ensuring they are made of stainless steel and are long enough to provide a secure hold.

It is worth noting that some T-tops may require additional stabilisation. Consider installing a stabiliser bar, especially if your console is smaller or if the stand-offs are positioned in a way that may affect stability.

Remember to take precise measurements and refer to the T-top's installation guide for specific instructions. Always double-check that your hardware is properly aligned and torqued to avoid any potential damage to your boat or the T-top itself.

Frequently asked questions