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

Aluminium boats are durable and long-lasting, but they can lose their shine and need to be refurbished to make the owner proud. Restoring an aluminium boat can be a lengthy process, but with the right tools and preparation, it can be done smoothly. This includes using an aluminium cleaner, gloves, goggles, and applicators, as well as removing adhesives from metals. The restoration process also involves tightening loose rivets, which can cause small leaks, and polishing the boat to bring out its shine.

Cleaning and polishing

The first step in reconditioning an aluminum boat is to thoroughly clean it. This will remove any built-up dirt, grime, mineral deposits, or algae. If your boat has been used in saltwater, there may also be barnacles on the hull that will need to be removed. A pressure washer is ideal for this task, but if you don't have access to one, you can use a regular hose and scrub with a towel or sponge.

Once the boat is free of dirt and debris, you can move on to treating oxidation. Oxidation is a common issue with aluminum boats, and it can give the boat an unsightly appearance. To remove oxidation, start by applying an aluminum cleaner to the hull. Use a plastic mesh scrubbing pad designed for boat hulls and scrub the cleaner into the aluminum using long, even strokes. This will help the cleaner penetrate and treat oxidized areas. After scrubbing, be sure to rinse the cleaner off with plain water and let the boat air dry.

With a clean and dry surface, you can now begin the polishing process. Apply an aluminum polish to the hull using a clean, dry cloth or wool pad. Work in small sections, using overlapping circular motions, until you've covered the entire aluminum surface. The polish will seal the aluminum and give it a uniform shine. If the cloth or pad becomes dirty, be sure to switch to a clean section or use a new pad to avoid rubbing oxidation back onto the hull.

Let the polish dry until it takes on a hazy or cloudy appearance. This usually takes around 5-20 minutes, depending on the product. Finally, buff the polish into the hull with a clean, soft, dry cloth, using circular or S-patterned motions. Work in small areas until the haze disappears and the boat shines.

To maintain the shine and reduce oxidation buildup, it's recommended to repeat the polishing process annually. Additionally, consider using a spray detailer designed to remove water spots and provide a streak-free finish. Regular maintenance will keep your aluminum boat looking its best for years to come.

Fixing loose rivets

The first step is to identify the extent of the problem. Fill the boat with water and check for leaks. If only a few rivets are leaking, the best solution may be to simply replace them. This can be done with a rivet gun and bucking bar, which are not expensive tools. However, if there are many leaking rivets, this may not be a practical solution.

One quick fix is to use a hammer to tighten the rivets. This can be done by placing a large hammer against the rivet from the outside of the boat and using a rod to strike the rivet from the inside. This method can be effective, but it may not be possible to access both sides of the rivet, and there is a risk of damaging the boat if not done carefully.

There are also several products available that can be used to seal leaking rivets. These include Glovit, JB Weld, and Muggy Weld Super Alloy 5. These products are typically applied around the rivet to create a water-tight seal. They are generally more expensive than other methods, but they can be effective in stopping leaks.

Another method to tighten loose rivets is to use a gas soldering iron and a plastic bottle. The rivet area is heated, and then the plastic is applied to create a seal. This method is fast and inexpensive, but it may not be as durable as other methods.

Finally, it is possible to drill out the old rivets and replace them with new ones. This method can be time-consuming, and it requires access to both sides of the rivet. It is important to note that drilling out rivets can weaken the structure of the boat, so it should only be done if necessary.

In summary, there are several methods to fix loose rivets on an aluminium boat. The best method will depend on the severity of the issue, the tools available, and the budget. It is important to address leaking rivets promptly to prevent further damage and ensure the safety of the boat.

Sanding and buffing

Sanding:

Before starting, ensure you have the right safety gear, including a respirator and protective eyewear. The sanding process will involve using progressively finer grit sandpaper to smooth out the aluminum surface:

• Initial Sanding: Start with a coarse grit sandpaper, such as 320 or 500 grit, to remove any scratches, gouges, or imperfections on the aluminum. This step is crucial if you want to achieve a mirror-like finish. Take your time with this step, as it lays the foundation for the final result.
• Progressive Sanding: Once the initial sanding is complete, gradually increase the grit of the sandpaper. Move to 800 grit, and then to 1200 grit. The goal is to remove the scratches left by the previous grit and create a smoother surface. Use a sanding block or a palm sander for flat surfaces, and be careful not to apply too much pressure, which can create uneven results.
• Final Sanding: Continue the sanding process with even finer grits, such as 180 and 220. The goal here is to refine the surface even further and create a consistent finish. It is essential to maintain a light touch during this step to avoid creating new scratches.
• Surface Preparation: After sanding, clean the surface thoroughly to remove any dust, residue, or debris. You can use a solvent, such as paint thinner, to ensure the surface is free of contaminants. This step is crucial for achieving the best results during the buffing process.

Buffing:

Buffing is the process of polishing the sanded aluminum surface to create a shiny and protective finish:

• Buffing Compound: Choose a suitable buffing compound, such as red tripoli or aluminum polish. These compounds will help cut through the remaining scratches and haze, bringing out the shine in the aluminum.
• Buffing Tools: You can use a variety of tools for buffing, including a linear buffer, angle grinder, or a handheld drill with buffing attachments. For hard-to-reach areas, a marine power mitt or a handheld buffing pad can be useful.
• Buffing Technique: When buffing, always work in a linear motion, following the grain of the aluminum. Avoid using a rotary motion, as it can create swirls and streaks that are difficult to remove. Take your time and work in small sections, ensuring that you cover the entire surface evenly.
• Final Touches: After buffing, rinse the surface with water to remove any black residue left by the buffing compound. You can then apply a protective coating, such as a wax or a specialized aluminum protectant, to preserve the shine and protect against oxidation.

Remember, sanding and buffing an aluminum boat is a labor-intensive process, but the results can be stunning. Take your time, work in a well-ventilated area, and always prioritize your safety when working with power tools and chemicals.

Sealing the boat

Sealing an aluminium boat is a crucial step in the reconditioning process. Here is a detailed, step-by-step guide to achieving a robust and complete seal for your boat:

Step 1: Identify Leaks and Problem Areas

Firstly, you need to identify the areas that require sealing. Leaks can occur at seams and rivets, so pay close attention to these areas. Dry the boat thoroughly and inspect for any signs of water ingress. While seams and rivets are the primary suspects, don't overlook other potential sources of leaks. Give the entire boat a thorough inspection before proceeding.

Step 2: Prepare the Surface

Once you've identified the problem areas, it's time to prepare the aluminium surface for sealing. Use a dedicated aluminium boat cleaner to ensure a high-quality clean while protecting the metal. Allow sufficient time for the aluminium to dry completely, ensuring a smooth and clean surface for the sealing process.

Step 3: Choose the Right Sealant

Selecting the appropriate sealant for your boat is vital. Opt for a sealant specifically designed to adhere to metal surfaces. Look for products that explicitly mention their suitability for use on metals, such as Life-Calk or acid-free Silicone Rubber Sealant, which won't corrode the aluminium. Reading labels carefully will help you make an informed decision.

Step 4: Apply the Sealant Liberally

When applying the sealant, don't be afraid to be generous. It's better to apply too much sealant than too little. You can always go back and scrape off any excess once the sealant has cured. Under-sealing may result in having to start over or dealing with tedious removal processes. Always read the product instructions to understand how to work with the specific sealant you've chosen.

Step 5: Cure and Test the Seal

Follow the directions provided by the manufacturer to ensure proper curing of the sealant. This may involve keeping the boat undisturbed overnight. After the curing process, carefully inspect the sealed areas and test them for water resistance. A proper cure will ensure that your seal is durable and effective.

Step 6: Consider Coating for Added Protection

While sealant plays a crucial role in leak prevention, consider applying a high-quality boat coating for added protection. A flexible and durable coating, such as Wetlander, can be applied over your seals, rivets, and the boat's floor or hull. This creates a double layer of protection and helps to reduce the vulnerability of rivets and seams to catching and tearing.

Step 7: Maintain and Inspect Regularly

Finally, remember that ongoing maintenance is essential to keep your boat in optimal condition. Regularly inspect your boat for any signs of leaks or damage. By promptly addressing any issues, you can prevent minor problems from becoming major headaches. Enjoy your reconditioned aluminium boat and the open waters it takes you to!

Painting the boat

Before painting, it is important to prepare the boat's surface. Sand off loose paint and rust to create a smooth surface. Depending on the size of the rusty patches, you might need a power sander and varying grit levels of sandpaper. Clean all the grime and dust off the boat. If you've waxed your boat previously, use a dewaxing solvent to remove traces of old wax. Mix a solution of mild soap and water in a spray bottle and wipe down the boat with a sponge. For tougher stains, mix a solution of 50% distilled vinegar and 50% warm water, spray it on the boat, and wipe it away after a minute. Rinse the boat with fresh water and, if you have time, polish it once it's dry.

When it comes to choosing a location for painting, opt for a rain-free day and set up your work area outside, away from cars and buildings. Put a piece of plastic down to catch any dripping paint and elevate the boat so you can easily access all areas of the hull.

Before painting, ensure that you have removed all rust, dirt, chipping paint, old wax, and polish. Apply a self-etching, oil-based primer that sticks to aluminum surfaces. Using a brush or sprayer, apply a thin layer of primer inside the boat and let it dry before painting the outside. The primer should dry overnight, or for at least 12 hours, before moving on to the painting process.

For the paint, choose a water-resistant marine paint that adheres to aluminum. Using a sprayer or brush, paint the inside of the boat first, using horizontal strokes for an even coat. Allow the inside coat to dry for around 12 hours before painting the exterior. The outside coat should also dry for the same amount of time. Consider adding a second layer of paint for extra protection. If so, be sure to let the first coat dry completely before applying the second.

Once the painting is finished, apply a clear protective coat to keep the paint intact and prevent scratches. Check the product label to determine how long this coat will need to cure before putting the boat in the water again.

Frequently asked questions