Remodeling Aluminum Boats: A Step-By-Step Guide To Success

Remodelling an aluminium boat can be a fun and rewarding project for those with the right tools and know-how. Whether you're an experienced boat remodeller or a novice, there are a few key steps to follow to ensure a successful project. From deconstruction and checking the rivets to sealing and painting, each stage requires careful attention to detail. This introduction will cover the basics of how to remodel an aluminium boat, providing an overview of the process and highlighting some of the key considerations for anyone planning to take on this endeavour.

Deconstructing the boat

Begin by removing all the components that will not be part of the final boat. This could include benches, gas tanks, anchors, batteries, ropes, and other gear. Be cautious when removing benches, as they are structural parts of the boat. If you do decide to remove a bench, reinforce the area, and drill out the rivets.

Next, assess the condition of the boat's structure. In the case of the boat in the example, the transom was rotten and needed to be replaced. The plywood seats had also eroded and needed to be replaced. Check the rivets, as these may need to be replaced. Old boats often used solid two-sided rivets on the major hull seams and blind rivets for the corner plates. Check the hull seams for leaks, and seal all seams and rivets.

Once you have identified the areas that need attention, carefully remove the relevant parts. For example, if you are replacing the seats, drill out the holes for the new hardware, and mark the holes for the seats' new hardware. If you are replacing the transom, you may need to cut and shape the plywood to fit, and add washers to the middle holes to provide extra support.

Finally, clean the boat thoroughly, both inside and out. Use a pressure washer to spray hard at the seams to check for leaks. This will also help to remove any remaining dirt, mould, or sand.

Checking and replacing rivets

To begin, inspect the boat for any signs of water leakage around the rivets. If leaks are present, it is important to note that the rivet itself is often not the sole cause of the leak. The issue may originate from a bent strake or another source, causing water to leak through the rivet. Identifying the root cause of the leak is crucial before proceeding with any repairs.

Once the source of the leak is determined, it is necessary to remove any previous repair attempts, such as epoxy or silicon, using an angle grinder with a sanding disc. This step ensures a clean surface for the new repairs. After the area is prepared, you can proceed with replacing the rivets.

When replacing rivets, it is recommended to use new aluminium rivets of the appropriate size, such as 3/16" rivets. Clamping and straightening the surface around the rivet holes may be necessary to ensure a proper fit. If drilling new holes is unavoidable, it is important to exercise caution and precision to avoid causing further damage to the boat.

In some cases, you may need to tighten existing rivets instead of replacing them. This can be achieved by using two hammers, with one person holding a heavy hammer on the rivet from one side of the boat while the other person peens the rivet from the opposite side. This process helps to secure the rivet and prevent leaks.

Cleaning and sealing the hull

Before you begin restoring your aluminium boat, it is important to give it a thorough clean. Start by removing everything you can from the boat, including the gas tank, anchor, battery, ropes, and gear. Next, scrub the boat to ensure all surfaces are free from mould, sand, or dirt. This step is particularly important if you plan on painting the boat.

Once the boat is clean, you can begin inspecting the hull seams and rivets for any damage or leaks. You can do this by borrowing or purchasing a pressure washer and spraying hard at the seams. If you find any leaks, make sure to seal them. Even if you don't find any leaks, it's a good idea to seal all the seams and rivets, especially if the boat is older.

When sealing the hull, remember to seal it from the outside. This is because the water pressure created by the boat's displacement will help the seals stay in place. A product like paint-on Flex Seal is a good option for sealing, as it really works and even adds some camouflage to the boat. While you can use a primer to help the paint stick to the Flex Seal, it's not necessary and may not be worth the extra effort.

After sealing, you may need to repair any breaches in the hull with a product like JB Weld. Prime and paint any shiny spots with a metal primer, and then coat the entire bottom of the boat with a protective layer, such as spray-on pickup truck bedliner. This will provide abrasion resistance and protection while also reducing drag by breaking up surface tension as the water runs along the hull.

Installing a new transom and seats

Preparing the Transom:

Start by creating a template for the new transom. Measure the width and height of the existing transom and add 2 inches to the height for additional support. Cut two pieces of 5/8" marine-glued plywood to size, following the template. Prime and paint both sides of the plywood, even the hidden areas, with a suitable primer and paint designed for moisture exposure.

Installing the Transom:

Bolt the new transom into place using the existing holes. Use stainless steel fender washers for any holes that may have been enlarged due to previous wobbling. Ensure the bolts are securely fastened to provide a sturdy base for the motor.

Reinforcing the Seats:

Inspect the aluminum thwarts that support the long dimensions of the seats. Cut a pressure-treated 2x6 to the appropriate angle and length to support the seats from below. Screw these supports into place inside the thwarts, ensuring they are level with the aluminum flanges. Shorten the EPS foam as needed to accommodate the new seat supports.

Installing the Seats:

Drill holes in the seats to match the hardware. Test-fit the seats to ensure proper alignment. Install the seats using their new hardware, securing them firmly in place.

Sealing and Finishing:

Seal all the stainless steel hardware with Flex Seal or a similar product to prevent rust and corrosion. Finally, apply a final coat of paint to the entire boat, including any camouflage patterns or designs desired for the exterior.

By following these steps, you can successfully install a new transom and seats in an aluminum boat, ensuring a stable and secure platform for your motor and providing comfortable and durable seating for passengers.

Painting the boat

Preparation

Before painting, it is essential to thoroughly clean the boat to ensure that the paint will adhere properly. Use a pressure washer to clean the boat inside and out, paying particular attention to the seams and rivets. If there is any mould, sand or dirt on the boat, scrub it away. Once the boat is clean, dry it completely.

Priming

Apply a primer to the aluminium surface to ensure that the paint will adhere properly. Look for a metal primer and apply it to any shiny spots or bare aluminium areas. For bare aluminium, you may also need to apply a cold galvanizing compound before the primer.

Painting

When choosing paint, opt for a spray-on variety designed for use on aluminium boats. You may want to choose a colour that will help camouflage the boat, such as a shade of green or blue. Carefully read the instructions on the paint to ensure that you are applying it correctly, including the recommended number of coats and drying time between coats.

Final Painting

Once the base colour is dry, you can add any additional colours or designs. For a camouflage pattern, choose a few complementary colours for a "major breakup" of the base colour. You can also add some darker accent colours to create shadows, movement, and a more realistic camouflage effect. Be careful not to overdo it with the darker shades, especially if the boat will be used in a marshy environment.

Sealing

After painting, seal the boat with a product like Flex Seal to protect the paint job and ensure that the seams and rivets are watertight. Paint the Flex Seal over any areas where stainless steel goes through wood or through the hull to prevent rust and corrosion.

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