Modifying Aluminum Boats: Tips And Tricks For Success

Aluminum boats are a popular choice for fishing and hunting enthusiasts due to their lightweight and sturdy construction. Modifying an aluminum boat can be a rewarding project for those with the necessary skills and creativity, as it allows them to customize their vessel according to their specific needs and preferences. Whether it's a small alteration or a complete overhaul, there are numerous modifications that can be made to enhance the functionality and appearance of an aluminum boat. This introduction will explore the various ways in which aluminum boats can be modified, providing inspiration and guidance for those looking to personalize their watercraft. From decking and seating arrangements to storage solutions and aesthetic enhancements, the possibilities are endless when it comes to transforming an aluminum boat into a tailored vessel for fishing, hunting, or simply enjoying a day on the water.

Removing and reinforcing structural components

Before removing any structural components, it is important to plan out the layout of your boat. This includes deciding how many people will be on board, whether they will be sitting or standing, and whether you will be adding a trolling motor.

One of the structural components that can be removed is the bench seat. Removing a bench seat can be done by drilling out the rivets. However, it is important to note that bench seats are structural parts of the boat designed to bear weight, so reinforcing the area after removal is crucial.

To reinforce the middle of the boat after removing a bench seat, you can use aluminum pieces riveted to the existing supports. For instance, you can use aluminum braces tied to the sides and floor of the boat, secured with rivets instead of screws.

If you have removed a middle bench, you may need to install new supports. This can be done by cutting and shaping aluminum pieces to fit vertically from the bottom of the boat up to the beams, providing additional support.

If you have removed any structural components, you can add support by connecting the side of the hull to the deck with 2x8 lumber. Cut triangular-shaped pieces of lumber and shape them using a Dremel or sandpaper to fit the hull. Use the holes from the removed rivets to secure the new structure with screws.

Additionally, when reinforcing the transom, which is the vertical reinforcement at the rear of the boat, you can add extra material to support the structure. Prepare the transom section, install the reinforcement, and attach any add-ons for stability.

Building a deck support skeleton

Planning the Deck Support Skeleton:

Start by taking accurate measurements of your boat, including its length and width, and the height at which you want the deck to be placed. Identify any existing structural elements like bench seats and determine potential mounting points for the deck supports. Calculate the available deck space, considering the size and layout of your boat.

Designing the Deck Support Framework:

The deck support framework typically consists of "ribs" and "beams". The "ribs" are 2" x 2" pieces of wood or metal that span across the width of the boat, placed at the desired height intervals, approximately 18" apart. The "beams" are also 2" x 2" pieces that run lengthwise, connecting the "ribs". Ensure the spacing between the "ribs" and "beams" is appropriate for the thickness of the plywood that will form the deck surface.

Additionally, add vertical supports to bear the load of the deck. The number and placement of these vertical supports will depend on the size of the deck and the thickness of the plywood. If you plan to have compartments or doors in the deck, you may need to adjust the framework accordingly.

Building the Deck Support Skeleton:

• Measure the width of the boat where the "ribs" will be located and cut the 2" x 2" pieces to this dimension.
• Use cardboard to create a template that matches the contour of the boat where the "rib" will be positioned. Lay the cardboard on the "rib" material and trace the shape onto both ends.
• Cut the "ribs" to shape using a jig saw, and refine the shape with a Dremel or sandpaper. Repeat this process for each "rib".
• Cut the "beams" from 2" x 2" pieces to fill the gap between the "ribs" running the width of the boat. Connect the "ribs" and "beams" with screws, ensuring a sturdy connection.
• Cut and shape vertical supports from 2" x 2" pieces, fitting them from the bottom of the boat up to the "beams". Secure these vertical supports with screws, adding more as needed for stability.
• For the rear support, cut a piece of plywood to fit the width and length of the rear seat. Attach a 2" x 2" piece along the width of the plywood, which will serve as a support for the rear storage doors.
• Cut and attach another 2" x 2" piece that spans the width of the boat and attaches to the transom, providing additional rear support.
• For the front support, cut a 2" x 2" piece to span the width of the boat, fitting it in front of the bow bench. Ensure it follows the shape of the hull. Cut a second parallel piece 13" forward, also shaped to match the hull. Cut two additional 2" x 2" pieces to fill the length between these two, screwing them together to form a sturdy assembly.
• Finally, cut another 2" x 2" piece that extends from the front assembly to the bow of the boat, shaping it to match the contour of the boat and screwing it into the middle of the assembly.

Additional Considerations:

• If you've removed any structural components like benches, you may need to add additional support to the sides of the hull. Use 2" x 8" lumber and cut triangular pieces to fit, securing them with screws.
• Always wear safety gear, including safety glasses and work gloves, when working on your boat.
• Consult resources like tinboats.net for further guidance and expert advice on aluminium boat modifications.

By carefully following these steps, you will create a strong and stable deck support skeleton, providing a foundation for the deck surface and ensuring the safety and functionality of your modified aluminium boat.

Painting and polishing

Cleaning and Preparation

First, you need to find a suitable space to dry-dock your boat. This could be a garage, shed, driveway, or even outdoors in front of your home. If none of these options are available, you can contact your local marina and rent or borrow a dry dock. It is important to elevate the boat off the ground so you can access all areas for painting. If you plan to use power tools, ensure you have access to electricity.

Next, you need to sand the surface of your boat to remove loose paint, rust, and embedded dirt. Use high-grit sandpaper and a power sander to eliminate rust patches. This process can take several hours, so don't rush it. After sanding, thoroughly wash your boat with a mixture of mild soap and water, and wipe it down with a sponge or rag. For embedded stains, create a solution of 50% warm water and 50% distilled vinegar, spray it on, wait a minute, then scrub. Alternatively, you can use special cleaning products from automotive or boating shops. After washing, rinse your boat completely to remove all soap and grime.

Polishing

Once your boat is clean and dry, it's time to polish. Do not use a generic polishing product. Instead, opt for an aluminium boat-specific polish, which can be found online or at automotive and boating stores. You can also use an aluminium cleaner that cleans, polishes, and protects. Apply the polish with a paintbrush or rag, or use a power buffer to speed up the process. However, you may still need to hand-buff hard-to-reach areas. Work in small sections, and make sure you don't miss any spots, as they will be noticeable after painting. Let the polish dry for 5 to 20 minutes, then wipe down the boat with a clean, dry cloth.

Painting

Choose a location for painting that is away from cars and buildings. Check the weather forecast and ensure no rain or wind is expected during the painting process. Put down a piece of plastic to catch any dripping paint and elevate the boat so you can access all areas.

Before painting, ensure the surface is free of rust, dirt, chipping paint, old wax, and polish. Use a power sander if necessary to create a smooth surface. Then, apply a self-etching, oil-based primer that adheres to aluminium. Use a brush or sprayer to apply a thin layer of primer inside the boat, then let it dry before priming the outside. Both layers will need about 12 hours to dry.

For the paint, select a water-resistant marine paint that sticks to aluminium. Aluminium-sticking paint comes in various colours, so you can customise your boat's look. As with the primer, paint the inside first using horizontal strokes for an even coat. Allow the inside coat to dry for 12 hours, then paint the exterior. The outside coat also needs 12 hours to dry. You may opt to add a second layer of paint for extra protection, ensuring the first coat is completely dry before applying the second.

Clear Coat

Finally, apply a clear protective coat to shield your boat's paint from scratches. This layer will also take several hours to dry, depending on the product you choose.

Adding storage and seating

You can create storage compartments by designing and building a support structure for the deck. This involves placing ribs (2" x 2"s) across the width of the boat, connected by beams running lengthwise. Vertical supports can also be added to bear the load of the deck. If you want to include storage doors, you'll need to adjust the placement of the ribs and beams accordingly.

When it comes to seating, you can opt to raise the seats by adding blocks of lumber underneath. Decide on the desired height and thickness of the blocks and cut them to size. Then, use 2 x 2's to anchor the blocks to the seats. Test the fit and make adjustments as needed.

Additionally, you can incorporate storage and seating by utilising the space under the seats. You can create compartments or hatches under the seats to store fishing gear, boating accessories, or other equipment. Ensure that the compartments are easily accessible and consider adding hinges and cabinet catches to the doors for security.

Remember to take precise measurements, plan your layout carefully, and always put safety first when modifying your aluminium boat.

Optimising for fishing and hunting

Aluminium boats are popular for fishing and hunting, and there are many ways to modify and optimise them for these purposes.

Firstly, consider the deck area. A flat-bottomed Jon boat is a good choice for modifications as it is easy to add storage, a casting area, cubby holes, platforms, and seating upgrades. A raised deck can provide additional storage and easy access to electronics, while also providing a sturdy platform for casting. Adding a casting area with everything within reach, such as electronics and fishing equipment, is a great way to optimise your boat for fishing.

When it comes to seating, pedestal swivel seats are a good option for fishing as they provide a stable platform and easy access to the trolling motor. If you want to optimise your boat for hunting, consider adding raised seating to get a better vantage point. You can also modify the seats by adding hatch door bench seating with storage underneath.

Another important consideration is storage. You can add compartments to the deck or use the space under the deck for storage. Fishing equipment, electronics, and batteries can be stored here. If you plan to hunt, you will need room for your gear, and possibly a dog. Bungee cord mounts are a good option for securing gear and stripping it down when necessary.

Finally, don't forget the finishing touches. Adding a fish finder, livewell, and rod holders can greatly improve your fishing experience. If you're hunting, consider painting your boat in camouflage colours and adding a duck blind. You may also want to upgrade your motor to a trolling motor, or go electric if gas motors are not allowed on your local lake.

Frequently asked questions