Removing Drain Tubes From Aluminum Boats: A Step-By-Step Guide

Removing the drain tube on an aluminum boat can be a challenging task, but with the right tools and guidance, it is certainly achievable. The process may vary depending on the specific design of your boat, but here are some general steps and suggestions to help you get started. Firstly, it is important to assess the condition of the drain tube and determine if it needs to be replaced. If the tube is made of brass, for example, it may be prone to corrosion and require replacement. Before beginning any work, gather the necessary tools, such as a screwdriver, drill, sandpaper, and a replacement drain tube.

One common method for removing the drain tube is to collapse the flared end by carefully tapping around the outside of the flare with a screwdriver and a hammer. This will push the walls of the tube inward, allowing you to drive it out. Alternatively, you can use a Dremel tool with a metal-cutting wheel to cut the tube in half from the inside and then carefully pop out each half. If the tube is sealed with an adhesive, you may need to drill it out. When installing the new drain tube, remember to seal it with marine-grade caulking or epoxy to prevent leaks.

Use a screwdriver and hammer to collapse the drain tube's flared end

To remove the drain tube on your aluminum boat, you will need a screwdriver and a hammer. Here is a step-by-step guide on how to use these tools to collapse the drain tube's flared end:

Firstly, select a screwdriver with an appropriately-sized head that fits into the flared end of the drain tube. Insert the screwdriver into the flared end, ensuring that it is aligned straight. This will help you apply force accurately to the flared end.

Next, take your hammer and strike the end of the screwdriver handle with it. Apply firm and controlled strikes to gradually collapse the flared end of the tube. Be careful not to strike the screwdriver at an angle, as this may cause the screwdriver to slip and damage the tube or surrounding boat structure.

Continue striking the screwdriver with the hammer until the flared end is collapsed and reduced in diameter. You may need to rotate the screwdriver and repeat the process from different angles to ensure the tube end is collapsed evenly.

Once the tube end is collapsed, carefully remove any debris or sharp edges that may have formed during the process. You can use a small file or sandpaper to smooth out any rough areas.

Finally, test the drain tube by inserting the plug. Make sure it fits snugly and securely. If necessary, make minor adjustments by gently tapping the tube with a rubber mallet or a soft-faced hammer to fine-tune the fit.

This method of using a screwdriver and hammer provides a simple and effective way to collapse the flared end of the drain tube on your aluminum boat.

Drill out the drain tube

If your drain tube is broken or damaged, you may need to drill it out. This can be done by using a screwdriver and hammer to collapse the flared end of the tube, allowing it to be pushed out. Alternatively, a Dremel tool with a metal-cutting wheel can be used to cut the tube in half from the inside, and then a screwdriver can be used to pop out each half. If the tube is particularly stubborn, you may need to use a drill to completely drill it out.

Once the old tube has been removed, you can prepare the hole for the new tube by cleaning and sealing the area. This may involve sanding or grinding the hole to smooth out any rough areas and applying a coat of resin or epoxy to seal the wood.

When installing the new tube, it is important to follow the manufacturer's instructions and take the necessary precautions. Some tubes may require the use of a flaring tool to flare the end of the tube, while others may need to be cut to the appropriate length and sealed with marine-grade caulking or epoxy. It is also important to use the correct type of tube for your boat. For example, brass tubes are standard for trailer boats but are not suitable for saltwater use, as they will eventually corrode.

Finally, be sure to have the correct plug for your new drain tube. The plug should fit snugly and be easy to remove and replace. Consider the location of the plug and whether you need to use a T-handle or lever-type plug for easier access.

Seal the replacement drain tube with resin

To seal the replacement drain tube with resin, follow these steps:

Firstly, ensure that the replacement drain tube is the correct size for your boat. The tube should fit snugly into the drain hole with minimal adjustments needed. You can find replacement drain tubes at marine supply stores or online. When purchasing, consider the diameter of the tube and the length that needs to be cut to fit your boat's transom width.

Next, clean the drain hole and remove any old sealant or debris. This will ensure a tight seal and proper adhesion for the new resin.

Before applying the resin, you may want to consider using a deep well socket to address any flaring or out-of-round conditions on the drain hole. This will help create a smoother surface for the resin to adhere to. Sanding or deburring the area with sandpaper can also help create a more even surface.

Now, it's time to apply the resin. Select a marine-grade resin or epoxy that is suitable for use above and below the waterline. Mix the resin according to the manufacturer's instructions, and apply it liberally to the cleaned drain hole.

Insert the male end of the replacement drain tube into the hole from the inside of the boat. Mark the thread on the tube where it comes out of the boat on the outside. Remove the tube and trim it to the appropriate length, following the manufacturer's instructions.

Fill the drain hole with additional resin. Apply resin to the male and female ends of the tube that will be in contact with the boat.

Reinsert the male end of the tube from the inside of the boat until it is seated. Push on the female end of the tube from the outside until it locks into place. Ensure that the threads on both ends engage securely.

Push from both ends to create a tight fit. The resin should ooze out, creating a watertight seal. Clean off any excess resin, including any that may have gotten inside the tube.

Allow the resin to cure completely according to the manufacturer's instructions before using your boat.

By following these steps, you will effectively seal your replacement drain tube with resin, creating a watertight and durable connection.

Flare the new drain tube

Flaring the new drain tube is a crucial step in ensuring a watertight seal for your aluminum boat. Here is a detailed guide on how to flare the new drain tube:

Step 1: Prepare the Drain Tube

Before you begin flaring, ensure that the new drain tube is cut to the correct length. It should be about a quarter to half an inch longer than the thickness of your boat's transom. This extra length will be used to create the flare that seals the tube in place.

Step 2: Gather the Right Tools

You will need a flaring tool, which you can purchase from marine supply stores or online. The basic flaring tool consists of a threaded rod with a washer and a conical die that will be used to flare the tube. You may also want to have some grease on hand to lubricate the threads of the tool and reduce the risk of splitting the tube.

Step 3: Prepare the Transom

Clean the area around the drain tube hole on both the inside and outside of the transom. Ensure that any old sealant or residue is removed. If there is any exposed wood, treat it with a sealant or epoxy to protect it from water damage.

Step 4: Insert the Drain Tube

Apply a generous amount of marine-grade sealant or epoxy, such as 5200, to the outside of the drain tube. Insert the tube into the hole, ensuring that it is seated properly and protrudes slightly on the inside of the transom.

Step 5: Flare the Drain Tube

This is the critical step in the process. Thread the flaring tool onto the drain tube from the inside of the transom. Ensure that the conical die is facing the end of the tube. Tighten the flaring tool gradually and evenly. As you do this, the die will press against the end of the tube, creating a flare that expands outward and seals the tube in place. Be careful not to over-tighten, as this can split the tube.

Step 6: Final Checks

Once you have flared the tube, carefully remove the flaring tool. Check that the tube is securely sealed in place by trying to move it back and forth. If it feels solid and doesn't leak, you have successfully installed the new drain tube.

Remember to always follow safety precautions when working with tools and sealants, and don't hesitate to seek professional assistance if needed.

Use a brass drain tube

If you're looking to replace the drain tube on your aluminum boat, you might want to consider using a brass drain tube. Brass drain tubes are standard items and last many years, even if they will eventually succumb to dezincification.

Before you start, make sure you have everything you need. You can buy brass tubing from marine supply stores or online. You'll also need a flange tool, which you can also buy online or, if you're lucky, get second-hand from another boat owner.

Once you have your materials, start by removing the old tubes. If the wood around the tubes is rotted, you'll need to grind it out and then fill the hole with epoxy or fiberglass resin. You may want to roughen the brass tubing with sandpaper before inserting it. Cut the tube about a quarter of an inch longer than the transom thickness, then coat it with 5200. Use the flange tool to swedge the tube in place, being careful not to over-tighten it or you may split the tube.

Some people also recommend heating the tube and dropping it into a bucket of water before installing it, to soften it and prevent splitting. You can also use a small amount of grease on the flange tool threads.

If you're not confident in your ability to replace the drain tube yourself, you can always take it to a welding shop to have it done professionally.

Frequently asked questions