Rebuck Rivets On Your Aluminum Boat Like A Pro

If you're looking to repair your aluminium boat, you may need to rebuck its rivets. This process involves tightening the rivets to stop leaks. To do this, you'll need a helper or long arms. One person will need to hold a buck (a hunk of steel) against the flat side of the rivet, while the other hammers the crimped end. You can use a ball-peen hammer to retighten the rivet head, or a carpenter's hammer to tighten. Be careful not to hammer too hard, as old aluminium rivets can split or break.

Identify the type of rivet and the thickness of the material

Before you begin rebucking the rivets on your aluminum boat, it is important to identify the type of rivets used and the thickness of the boat material. This will help ensure that you use the correct tools and techniques for the job.

Identifying the Rivet Type

Rivets come in many types, each designed for specific cost, accessibility, and strength requirements. The most common types of rivets are solid/round head rivets, semi-tubular rivets, and blind rivets. Solid rivets are one of the oldest types of fasteners and are simply a shaft and head that are deformed with a hammer or rivet gun. Semi-tubular rivets are similar to solid rivets but have a partial hole at the tip, which reduces the force needed for application. Blind rivets, also known as "pop" rivets, are tubular and supplied with a nail-like mandrel through the center. They can be installed with access to only one side of the structure.

To identify the type of rivet used in your aluminum boat, examine the rivets themselves. Solid rivets will have a shaft and head, while semi-tubular rivets will have a partial hole at the tip opposite the head. Blind rivets will have a nail-like mandrel through the center. You can also refer to the boat's manufacturer or a marine specialist for specific information about the rivets used in your boat model.

Identifying the Material Thickness

The thickness of the aluminum boat material is important to know as it will affect the strength and durability of the boat. Thicker material generally provides more strength and rigidity, while thinner material may be lighter and more flexible.

To identify the thickness of your aluminum boat material, you can refer to the boat's specifications or user manual. It should provide details about the material thickness for different parts of the boat, such as the hull, deck, or sides. Additionally, you can use a caliper or a micrometer to measure the thickness of the material directly. Measure at multiple points to ensure consistency.

The thickness of the material will also influence the type of rivets and installation techniques used. Thicker materials may require larger-diameter rivets and more robust installation tools. It is important to use the appropriate rivets and techniques for your boat's specific material thickness to ensure a secure and long-lasting fastening.

By taking the time to identify both the type of rivets and the thickness of the boat material, you can ensure that you have the right tools and knowledge to successfully rebuck the rivets on your aluminum boat.

Use a bucking bar or heavy hammer to hold the rivet in place

When rebucking a rivet, you will need a helper or long arms. One of you will hold the buck—any anvil-like hunk of steel, or a bucking bar—tightly against the flat side of the rivet. It is important to use a flat and perfectly smooth surface to avoid damaging the rivet or the boat. You can also use the head of a sledgehammer or a heavy hammer as the buck.

If you are using a bucking bar, it should be held perpendicular to the rivet before and while hammering. If you are using a heavy hammer, you can use a ball-peen hammer to retighten the rivet head. If you are working with an assistant, they can hold the bucking bar or heavy hammer in place while you strike the rivet with a hammer. Make sure to strike the rivet a few times to tighten it properly.

If you are working alone, you can try using a carpenter's hammer to tighten the rivet. Place the bucking bar or heavy hammer on the rivet and use the carpenter's hammer to strike the rivet a few times.

It is important to avoid too much hammering when rebucking a rivet. Old aluminum rivets can split or break if you give them a heavy whack.

Hammer the crimped end of the rivet with a ball-peen hammer

To rebuck a rivet, you will need a helper or long arms. One of you will hold the buck, a heavy hammer, tightly against the flat side of the rivet, while the other hammers the crimped end with a ball-peen hammer. The ball-peen hammer is important as it will help you retighten the rivet head.

When hammering the crimped end of the rivet, it is important to be careful and avoid too much hammering. Old aluminium rivets can split or break if you give them a heavy whack. You want to hammer the rivet enough to tighten it, but not so much that you damage the rivet.

If you do not have a ball-peen hammer, you can also use the face of a sledgehammer as the buck and a carpenter's hammer to tighten. Alternatively, you can use a heavy hammer as the buck and a brass punch and hammer to tighten the rivet.

Avoid heavy whacks to prevent splitting or breaking the rivet

When rebucking rivets on an aluminum boat, it is important to avoid heavy whacks to prevent splitting or breaking the rivet. Here are some tips to help you achieve this:

• Use the right tools: Ensure you are using the correct rivet gun and bucking bar for the job. The rivet gun should be pneumatic or two-handled for setting solid rivets, while the bucking bar should be flat and heavy. Using the wrong tools can result in insufficient force to properly set the rivet or can damage the rivet and the boat.
• Apply moderate force: When using the rivet gun, avoid excessive force. Hitting the rivet too hard can cause it to break or become brittle, and can also crack the metal of the boat, leading to leaks and other issues. Apply steady, controlled pressure to set the rivet correctly.
• Practice proper technique: Position the bucking bar perpendicular to the rivet before and during the rebucking process. Hold it firmly in place while pulling the trigger on the rivet gun. Ensure that you and any assistants are well-coordinated to achieve precise and controlled strikes.
• Choose appropriate rivets: Select rivets that are softer than the aluminum of your boat. This ensures that the rivets become the "weak link" and can be replaced without damaging the hull. Using rivets that are too hard can result in cracks in the boat's metal.
• Inspect your work: After rebucking a rivet, take a close look at the surrounding metal for any signs of damage, such as cracks or dents. Also, examine your "good" rivets to ensure they are properly set and not just "barely hanging on."
• Seek alternative methods: If you are consistently breaking rivets, consider using an alternative method such as epoxy or adhesives to repair leaks and secure joints. While rivets are ideal, in some cases, a different approach may be necessary to achieve a watertight seal.
• Practice on scrap metal: Before attempting to rebuck rivets on your boat, practice on a piece of scrap aluminum of similar thickness. This will help you get a feel for the required force and technique without risking damage to your boat.

If the rivet is damaged, source a replacement solid aluminium rivet

If the rivet is damaged, you will need to source a replacement solid aluminium rivet. You can find these at specialist suppliers, such as Jay-Cee Rivets, Aircraft Spruce & Specialty, or JayCee. You can also find rivets on Amazon, but be sure to check the reviews and buy from a reputable seller.

When sourcing replacement rivets, it is important to get the right size. The rivet should be total thickness + 125% of the rivet diameter long. For example, if your rivet has a diameter of 3/16" , you will need a rivet that is 3/8" long. It is also important to get the right type of rivet. Solid rivets are best for this purpose, and you should use brazier head rivets for below the waterline. Blind rivets can be used for interior parts and above the waterline.

When you have your replacement rivets, you will need the right tools to install them. You will need two hammers, one preferably heavy, and a bucking bar to tap against the rivet. You can also use an air hammer with a bit for an air tool, or a pneumatic riveter.

Frequently asked questions