
Aluminium boats are beloved by many for their durability and longevity. However, like any vessel, they require maintenance and care to keep them in good condition. Over time, aluminium boats can become damaged or corroded, especially if they are frequently used in saltwater environments. This is where restoration comes in. The process of restoring an aluminium boat involves several steps, including cleaning, repairing, sealing, and painting. It is important to carefully inspect the boat for any signs of damage, such as loose or corroded rivets, holes, or leaks, and address these issues to ensure the safety and functionality of the boat.
How to Restore an Aluminum Boat
Characteristics | Values |
---|---|
Clean the boat | Use a pressure washer to clean the boat inside and out. Spray with Algex, scrub, and wash off with a pressure washer or hose. |
Remove corrosion | Use a scrub brush to remove corrosion and marine growth. |
Buff the surface | Use Alumabuff, a Linear Buffer, an Alumabuff Pad Kit, and a Marine Power Mitt to buff the surface. |
Protect the boat | Apply 4 thin coats of Alumetron to protect the bottom of the boat. |
Add scratch resistance | Apply 2 coats of VS721 for scratch resistance and to extend durability. |
Seal the boat | Use Flex Seal to seal the boat from water. |
Paint the boat | Paint the boat with an epoxy coating, such as Gator Glide. |
Fix holes | Spot fill the holes by taking the boat to a welding shop or using a low-heat aluminum welding rod and a handheld propane torch. |
Fix loose bolts and screws | Replace loose bolts and screws with new ones. |
Fix eroded seats | Cut and paint plywood to replace eroded seats. |
Fix leaking rivets | Replace leaking rivets with sealed aluminum rivets and a hand riveter. |
What You'll Learn
Clean the boat with a pressure washer
Cleaning an Aluminum Boat with a Pressure Washer
Using a pressure washer is an effective way to clean your aluminum boat. It can reduce the time and effort needed to clean your boat and is useful for regular maintenance. Here is a step-by-step guide on how to clean your aluminum boat with a pressure washer:
Step 1: Prepare the Boat
Once you have finished sailing for the day, get the boat onto land and attach the pressure washer soap nozzle to your garden hose. It is important to perform this cleaning process as soon as you can after taking the boat out of the water, as the dirt and grime will be easier to remove when it is still wet.
Step 2: Apply Soap
Spray the boat with biodegradable car soap, starting from the bottom and working your way up. Allow the soap to soak for about 5 minutes. Ensure that the soap does not dry, as this will create an extra layer of grime for you to clean off.
Step 3: Pressure Wash
Rinse the boat thoroughly with the pressure washer, working from the top to the bottom. Pay particular attention to the hull, as this is the part of the boat that is most exposed to dirt and grime. Double-check that all the detergent has been washed off the vessel, and flush out the motor.
Step 4: Dry the Boat
After pressure washing, ensure that you dry the boat thoroughly. You can use a cloth or chamois to wipe down the surfaces and remove any remaining water. This step is important to prevent water spots and streaking.
Step 5: Inspect and Repeat
After cleaning and drying the boat, take some time to inspect it for any remaining dirt or grime. If there are still areas of dirt, you may need to repeat the process, paying particular attention to those areas. You may also need to use a scrub brush or soft cloth to work away at stubborn dirt.
Tips for Using a Pressure Washer:
- Be careful not to use too much pressure when washing, as this can damage the surface of the boat.
- Always follow the manufacturer's instructions for your pressure washer, including safety guidelines.
- If your boat has a lot of built-up grime, you may need to be more generous with the amount of soap and water you use.
- For best results, clean your boat regularly, both inside and out, to prevent major problems from developing.
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Seal the boat with Flex Seal
Sealing your aluminium boat with Flex Seal is a great way to ensure your boat is protected and ready for the elements. Here is a step-by-step guide to achieving a successful seal:
Preparation
Before you begin, it's important to wear protective clothing and read all the directions for applying Flex Seal. Make sure you have cleaned the intended area and allowed it to dry thoroughly. Check the weather forecast and ensure no rain is expected for at least 24 hours after application.
Application
Flex Seal can be brushed, poured, or rolled on. Apply one coat at a time, always letting each coat dry before adding the next. Multiple coats can offer more protection, but be sure to follow the instructions and allow sufficient drying time between coats. Flex Seal dries to the touch in 2-3 hours and fully cures in 24-48 hours. When patching a hole, extend the product well past the hole to ensure complete coverage. For example, if the gash is 2 inches wide, add another inch of Flex Seal on either end.
Sealing
Flex Seal works well with aluminium, so it's an excellent choice for sealing your boat. It can be used to repair gashes or holes, and it bonds well with aluminium, making it a great option for pontoon boat repairs. Flex Seal is also ideal for sealing around rivets to prevent leaks.
Painting
While Flex Seal can be painted over, it's important to note that paint may not adhere to it very well. If you choose to paint over Flex Seal, consider using a plastic primer first, although this may not be necessary.
Maintenance
Flex Seal will help protect your boat from leaks and corrosion, but it's important to maintain your boat regularly. Check for any signs of damage or corrosion and address them promptly. Remember, sealing your boat with Flex Seal will help protect it, but it's essential to combine it with proper maintenance and care for your boat.
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Repair loose bolts and rivets
Before you begin to repair loose bolts and rivets on an aluminium boat, you must first identify the leaking culprits. You can do this by beaching your boat and gradually sliding it into the water foot by foot, marking the rivets that leak as you move along. Alternatively, you can get the boat off the ground, fill it to the waterline with water, and mark the leaking rivets.
Once you have identified the leaking rivets, you can begin the process of repairing them. To rebuck (tighten) a rivet, you will need an assistant or long arms. One person will hold the buck (an anvil-like hunk of steel) tightly against the flat side of the rivet, while the other hammers the crimped end. Tools such as an automotive bodywork dolly or a ball-peen hammer can be used to retighten the rivet head. It is important to avoid too much hammering, as old aluminium rivets can split or break if hit too hard.
If you accidentally split or break a rivet, you will need to source solid aluminium rivets from marine supply houses or sheet metal vendors. To remove the old rivet, file or grind off one head, or drill it out, being careful not to enlarge the hole. When seated in its hole, the new rivet's unpeened (headless) end should protrude by about 2/3 of its diameter. For the best hold, "set" the rivet first so that the metal sheets are in tight contact. Drill a hole just larger than the rivet's diameter in a hardwood dowel or steel bar. Put the rivet in its hole and your buck against the rivet head. Slip the dowel over the unpeened end—a solid hammer blow will cinch everything up, ready for you to shape the rivet head.
As a temporary solution until you can install a new rivet, you can use a small stainless steel machine screw with an acorn nut. Flexible marine epoxy or sealant, applied to the hole before tightening, will help this repair last longer.
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Sand and scrape the aluminium
Sanding aluminium can be brutal on the material and is not recommended. It is also important to avoid abrasive cleansers or solvents that could damage the finish. Instead, use a chemical paint stripper, which is easier and cheaper. After applying the stripper, use a plastic spatula or a metal scraper to scrape the paint off.
If you do decide to sand, a random orbital sander can be used to create an interesting, white-ish finish that holds up well over time. Use 60-grit green 3M paper on a quarter-sheet Dewalt sander.
Alternatively, you could try sandblasting, but be aware that sand is too aggressive for aluminium and will damage the hull. Instead, use a gentler medium like glass beads, soda, or walnut shells.
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Apply epoxy coating to the bottom of the boat
To apply an epoxy coating to the bottom of your aluminium boat, you will need to first ensure that the surface is clean and free of any dirt, loose paint, or oxidation. Start by power washing the boat, and then scrape, sand, and wire brush the surface to remove any remaining debris or paint. You can then spray the boat with a cleaning agent, such as vinegar, to remove any oxidation from the aluminium, and power wash it again.
Once the surface is clean and dry, you can begin to apply the epoxy coating. Make sure you are working in a well-ventilated area and follow the instructions on your chosen product for the best results. It is recommended to apply several thin coats of epoxy rather than one thick coat. For example, you can apply four thin coats of Alumetron, which can last up to 10 years and comes with a warranty.
After the epoxy has dried, you may wish to add an additional layer of protection. Two coats of VS721 can add scratch resistance and extend the durability of the epoxy coating. This will also help to reduce marine growth and improve the performance of the boat.
Finally, remember to allow adequate curing time for the epoxy coating before launching your boat.
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Frequently asked questions
The first step is to deconstruct the boat to identify what needs to be repaired or replaced.
You can use a product called "Alumi-brite" to clean the boat. You can also pressure wash it to remove dirt and loose paint.
You can bring the boat to a welding shop to spot-fill the holes.
You can use a product called "Flex Seal" to seal the boat. It is recommended to seal the boat from the outside, as this will utilise water pressure to strengthen the seals.
You can use epoxy coating, such as "Gator Glide", on the bottom of the boat. For the rest of the boat, you can prime it with a self-etching primer and then paint it with a product like "Rustoleum".