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

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

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.

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.

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.

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.

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.

Frequently asked questions