Removing Aluminum Boat Seats: A Step-By-Step Guide

Removing seats from an aluminium boat is a common topic of discussion in boating forums. Many boat owners are interested in removing bench seats to create more space, but it is important to consider the structural impact this may have on the boat. The bench seats in aluminium boats often serve as structural bulkheads that stiffen the centre section of the boat and prevent the sides from flexing outwards. Removing these seats can cause the boat to become more flexible and unstable, especially if it is a narrow boat. However, some boat owners have successfully removed bench seats and added alternative structures, such as floors or storage boxes, to provide additional support. It is recommended to carefully plan and consider the potential impact on the boat's structure before removing any seats.

Removing a bench seat from an aluminium boat

Step 1: Assess the Boat's Structure

Before removing any seats, it's crucial to understand how the boat is constructed. In many aluminium boats, the bench seats are an integral part of the structure, providing support and preventing the sides from flexing or spreading apart. Removing these seats without proper reinforcement can weaken the boat and lead to cracking or failure.

Step 2: Decide on the Scope of the Project

If you have multiple bench seats, consider which ones you want to remove. Removing all the seats may not be advisable, as it could compromise the boat's integrity. Some boats have a rear seat that should not be removed, while others have a front deck that adds more stability than a centre seat. Assess your boat's design and decide which seats can be safely removed.

Step 3: Plan for Reinforcement

If you decide to remove a bench seat, you must replace the structural support it provides. This can be done by adding a stiff wooden railing or aluminium bar along the gunwales (top edges of the boat's sides) to add rigidity to the sidewalls. Consider adding a floor or storage boxes that tie into the hull and provide additional support.

Step 4: Prepare the Necessary Tools and Materials

Gather the tools and materials needed for the job. This may include items such as a jigsaw with a metal-cutting blade, rivets, aluminium flat bars or angles, plywood or aluminium sheets for flooring, and paint to match your boat's colour.

Step 5: Remove the Bench Seat

Carefully cut out the bench seat, ensuring you don't damage the surrounding structure. You may need to drill out rivets that hold the seat in place. If possible, cut close to the sides to avoid having to fill or cover the remaining holes.

Step 6: Reinforce the Structure

As mentioned in Step 3, add the necessary reinforcements to compensate for the removed seat. This could include installing aluminium bars or railings, or building a floor that ties into the hull and adds stiffness. Ensure that any new additions are securely fastened to the boat's ribs or stringers.

Step 7: Finish and Paint

Once the new structure is in place, you can add a finishing touch by covering any exposed metal edges with plywood or aluminium sheets, and painting them to match the boat.

Important Considerations:

• Safety: Be mindful that bench seats often contain flotation foam, which is crucial if your boat gets swamped. Consider adding closed-cell foam to another part of the boat to compensate for any loss of flotation.
• Stability: Removing a bench seat and replacing it with a floor can raise the boat's centre of gravity, making it more unstable, especially in choppy waters. Assess the boat's width and stability before making any changes.
• Flexing: Test the boat for flexing by grabbing the corners at the bow and trying to twist the hull. If it twists significantly, reinforcement is necessary to prevent damage.

How to cut out the middle of a bench seat

To cut out the middle of a bench seat in an aluminium boat, you will need to consider the structural impact on the boat. The bench seat may be part of the structure of the boat, so removing it could cause the boat to flex and bend.

First, assess the structure of your boat. Look at the size and spacing of the ribs, the gunwales, and the profile of the gunwales. Compare these to boats designed to be open, and those designed to have a centre bench as structural support. You will be able to see the difference.

If you decide to go ahead, you will need to replace the structure that the centre seat provides. You can do this by adding a stiff wooden railing down the sides under the gunwales to add back some stiffness and stability to the side walls. You could also add a floor, but this may not be enough on its own.

Another option is to cut out a section of the bench to create a walkthrough, while leaving the sides of the bench in place to maintain the structure. You can then enclose the remaining seat sections for storage.

If you do decide to remove the entire bench, you will need to cut it out close to the sides. Tap the excess metal so that it doesn't stick out past the side ribs. You can then cover the excess metal with plywood or aluminium, painting it the same colour as the boat.

Remember to consider the flotation of the boat. The bench seat may contain foam that aids flotation if the boat is swamped. You will need to replace this with closed-cell foam somewhere else in the boat.

Reinforcing an aluminium boat after removing seats

To reinforce an aluminium boat after removing seats, you must first consider the size, length and overall proportion of the ribs of your boat, as well as the size and profile of the gunwales. Look at boats designed to be open and compare them with boats designed to use the centre bench as structural support. The difference is clear, and they are made that way for a reason.

If you want to remove a centre seat, you can replace the structure it provides with a deck. However, simply putting in a floor and removing the seat is not recommended. The centre seat keeps the boat from flexing in the middle, so you need to replace that stability by adding stiffness to the sidewalls.

One way to do this is to add a stiff wooden railing down the sides under the gunwales. You could also add side storage boxes or rod storage lockers to each side. Anything that will stiffen the sides of the hull will work.

If you want an open walkway but also need storage, you could split the seat and make two separate storage areas. You can keep the structural strength by anchoring it to the ribs with aluminium bar.

Another option is to cut out the middle of the seat and add a stiff wooden railing down the sides. You can also add a floor to help hold the seat down.

If you do decide to remove the seats, it is recommended to save them in case you need to put them back in.

Removing seats from a riveted boat

Before starting, it is essential to assess the structure of your boat. Examine the placement and spacing of the ribs and gunnels. The ribs provide support to the boat, and their position will influence the impact of removing the seats. Additionally, consider the overall length and proportions of your boat. Longer boats are more prone to flexing without the structural support of the seats.

Now, let's begin the process of removing the seats:

• Safety First: Ensure you are wearing appropriate safety gear, including eye protection and gloves, to protect yourself from any sharp metal edges or debris.
• Prepare the Work Area: Gather all the necessary tools and materials, including a drill, rivet gun, hammers, and rivets. Set up a stable work area near your boat, preferably with a flat surface to place the removed seats.
• Assess the Seats: Inspect the seats and their attachment to the boat. Determine if they are connected to the floor or the sides of the boat. Look for any braces or supports that may need to be removed or adjusted.
• Drill Out Rivets: Start by drilling out the rivets that secure the seats to the boat. Carefully drill through the center of each rivet, being mindful not to damage the surrounding material. Collect the removed rivets for future use if they are in good condition.
• Remove the Seats: Once the rivets are drilled out, carefully pry or lift the seats away from the boat. You may need to use a flathead screwdriver or a similar tool to gently loosen any stubborn connections. Set the removed seats aside in your designated work area.
• Reinforce the Structure: At this point, it is crucial to assess the boat's structure and rigidity. As the seats often provide structural support, you may need to add reinforcement to prevent flexing or twisting. Consider adding aluminum bars or railings along the sides of the boat to enhance stiffness.
• Fill Rivet Holes: To maintain the integrity of your boat, fill in the holes left by the removed rivets. You can use silicone or a similar waterproof sealant to fill and smooth over the holes, ensuring a watertight seal.
• Clean and Inspect: Clean the area where the seats were removed, removing any debris or leftover sealant. Inspect the boat for any signs of damage or weakness. Address any issues that may impact the safety or performance of the boat.

Remember, always exercise caution and good judgment when modifying your boat. If you are unsure about any aspect of the process, it is best to consult a professional or seek advice from experienced boat enthusiasts or forums.

Additionally, consider the impact of removing the seats on the boat's flotation and stability. Some seats may contain foam or serve as a crucial component for flotation. Assess whether you need to add additional flotation devices or make other adjustments to ensure the safety of your vessel.

Replacing boat seats with a floor

If you're looking to replace your boat seats with a floor, there are a few things you should keep in mind. Firstly, it's important to note that boat seats are often part of the structure of the boat, providing support and stability. Removing them can affect the boat's integrity, so you must carefully consider the design and material of your boat before making any changes.

Removing the Seats

When removing the seats, start by checking if they are bolted or welded to the boat's structure. If they are bolted, carefully remove the bolts and set them aside, as you may need them later. If the seats are welded, you will need to cut them out, being extremely cautious not to damage the boat's hull. In both cases, it is recommended to seek professional advice or assistance if you are unsure about the process.

Installing a New Floor

Before installing a new floor, ensure that it is made of a sturdy material that can withstand the weight and stress of being on the water. It should also be properly sealed to prevent water damage. Measure the area where you plan to install the floor and cut the flooring material to size, allowing for any necessary adjustments. When installing the floor, use strong adhesives and sealants to secure it in place, following the manufacturer's instructions.

Adding Support

As mentioned earlier, removing the seats can affect the boat's stability. To compensate for this, consider adding support structures such as stiff wood railings or aluminium bars along the sides of the boat. These additions will help to reinforce the hull and reduce flexing. It is crucial to consult with a professional or an engineer to determine the best support structures for your boat's specific design.

Final Thoughts

While replacing boat seats with a floor can be a significant change, it is possible to do so safely. Always remember to prioritise the structural integrity and stability of your boat. If you are ever in doubt about the process, don't hesitate to consult with experts in boat maintenance and repair.

Frequently asked questions