Untwisting Your Aluminum Jon Boat: A Step-By-Step Guide

If you're looking to untwist an aluminum Jon boat, you've come to the right place. While it's certainly a challenge, it's not impossible. One method is to use ropes and muscle power to twist the boat back into shape, perhaps with the help of a trailer for stability and leverage. Alternatively, you could try drilling holes and using wood to brace the affected area, then employing a come-along tool to pull out the dent and straighten the twist. It's important to note that removing the seats in a Jon boat may reduce its strength, so caution and reinforcement are advised.

Drilling out rivets and replacing with bolts

Drilling out rivets and replacing them with bolts is a common practice when modifying aluminium Jon boats. Here is a step-by-step guide on how to do it:

Tools and Materials:

• Drill
• Stainless steel bolts
• Nylon washers
• Nylon lock nuts
• Fender washers
• Sealant

Drilling Out the Rivets:

Before drilling, make sure to wear appropriate safety gear, including eye protection and gloves. Identify the rivets that need to be replaced and use the drill to carefully drill them out. Ensure that you don't push too hard on the drill, as you don't want to distort the holes. Drill only to the depth of the rivet head and then use a punch to drive out the remaining portion of the rivet.

Preparing the Holes:

Clean the aluminium surface around the holes with a solvent and a scotch-brite pad to remove any residue or corrosion. Apply a primer or sealant to the holes to prevent corrosion and create a better seal for the new bolts.

Installing the Bolts:

Insert the stainless steel bolts through the holes from the outside of the boat. Use nylon washers between the bolt head and the aluminium surface to prevent galvanic corrosion. On the inside of the boat, add fender washers and nylon lock nuts to secure the bolts in place. Tighten the bolts securely, but be careful not to over-tighten, as this can distort the metal.

Sealing:

Apply a marine-grade sealant or silicone around the bolt heads and nuts to create a watertight seal. This will help prevent leaks and protect the aluminium from corrosion.

By following these steps, you can safely drill out rivets and replace them with bolts when modifying your aluminium Jon boat. Remember to take your time, work carefully, and use the appropriate tools and materials to ensure a strong and secure modification.

Using a trailer to twist the boat

To untwist an aluminium Jon boat using a trailer, follow these steps:

Firstly, place the boat on the trailer, ensuring it is securely fastened and won't shift during the process. This will provide a stable base to work from and allow you to access all areas of the boat. Next, you'll need to assess the severity of the twist. Measure the boat's dimensions and note the areas that are out of alignment. Mark these spots, so they are clearly visible.

Now, you can begin the process of twisting the boat back into shape. Using ropes or straps, apply pressure to the areas that need adjustment. You may need to experiment with different leverage points and techniques to find the most effective method for your particular boat. It may be helpful to have some muscle power on hand to assist with the twisting, and the application of some force.

During the process, regularly check your progress by measuring the boat again and comparing it to the ideal dimensions. This will ensure you are on the right track and allow you to make any necessary adjustments. Take your time, as rushing this process could lead to further damage or an uneven result.

Once you are satisfied that the boat is as close to its original shape as possible, you will need to secure it in place. This can be done by clamping, welding, or using other fastening methods to hold the boat in its corrected position. Again, take your time with this step to ensure the boat is secure and won't shift or twist back.

Finally, inspect your work thoroughly. Check for any signs of stress or weakness in the structure, and address these as needed. You may wish to consult with a professional boat builder or repairer to ensure the boat is safe for use once again.

Remember, this is a general guide, and the specific steps may vary depending on the unique characteristics of your boat and the severity of the twist. Always exercise caution and use appropriate safety measures when working with heavy objects and equipment.

Adding aluminium brackets to the hull

Aluminium brackets can be a great addition to your jon boat, providing more room inside and improving performance and handling. There are two main types of brackets: standard and floatation. A standard bracket is a square box with a flat bottom, while a floatation bracket has a point at the bottom to help level off your boat.

When adding aluminium brackets to the hull of your jon boat, it is important to consider the design and material carefully. Here are some detailed steps and tips to guide you through the process:

• Design and Planning: Before beginning any modifications, it is crucial to have a clear understanding of the design and measurements. Determine the size and placement of the brackets, ensuring they will fit your boat's transom and engine. Consider the setback and platform size, which typically range from 18" to 36" for the setback and 60" to 96" for the platform.
• Materials: Choose high-quality aluminium that matches the alloy your boat was built with. You can contact the boat manufacturer or factory to obtain this information. Ensure you have all the necessary hardware, such as bolts, nuts, washers, and rivets. Use stainless steel or nickel-plated hardware to prevent corrosion.
• Fabrication and Installation: Cut the aluminium pieces according to your design. Consider using a skilled welder for this step if you are not confident in your welding abilities. You can also explore other cutting methods, such as using a skilsaw or waterjet cutting. Drill holes and attach the brackets to the hull and engine using the appropriate hardware. Ensure all connections are secure and sealed with marine sealant or silicone to prevent water ingress.
• Finishing: Powder-coating your brackets can provide additional protection against saltwater conditions. You can also paint or coat the brackets to match the colour of your boat for a more seamless look. Consider adding a non-skid texture to the platforms for improved safety.

Remember to always take appropriate safety precautions when working with tools and equipment. It is recommended to wear protective gear, such as gloves and eye protection, during the fabrication and installation process. Additionally, ensure you have a clear and safe workspace before beginning any modifications.

Adding a wood floor to the boat

Adding a wooden floor to your Jon boat can improve comfort, safety, and usability. However, it will also add weight, which will reduce the maximum capacity of the boat. Here is a step-by-step guide to adding a wooden floor to your Jon boat:

Planning:

First, consider what you will be using the boat for. For example, if you plan to use it for duck hunting, you will need a floor that can be easily cleaned after a day of muddy boots and wet dogs. On the other hand, if you are planning to use it for fishing tournaments, you might want a more finished look.

Materials:

The base layer of your floor should be Extruded (XPS) Polystyrene. This is the pink or blue foam insulation that doesn't make a mess when you cut it. On top of the XPS foam, you can use various materials depending on your needs:

• Thin plywood treated with paint
• Puzzle-like workout/gym mats
• Horse mat (available in different thicknesses)
• Plywood with carpet on top
• Metal floor (if you have a welder and metalworking tools)

Measurements:

Take precise measurements of your boat to ensure that your floor fits perfectly. Consider the thickness of the foam and the top material you will be using. If you plan to use bolts or other hardware for fastening, measure the length of these as well.

Installation:

You can attach the floor to the ribs of the boat using bolts, washers, and rivnuts/nutserts. If you prefer not to drill holes in your boat, you can use adhesives to glue the floor in place.

Finishing:

Paint your wooden floor to protect it and ensure it lasts a long time. You can also add carpet on top of the plywood for a more finished look and added comfort.

Weight Considerations:

Be mindful of the added weight of the wooden floor. This will reduce the maximum capacity of your boat and could affect its performance. If weight is a concern, consider using lighter materials such as aluminium sheeting or rubber mats.

Maintenance:

Wooden floors will require regular maintenance to prevent rotting and ensure longevity. If you plan to store your boat outdoors, consider using materials that are more resistant to the elements, such as aluminium or rubber.

By following these steps, you can successfully add a wooden floor to your Jon boat, improving its comfort and functionality while being mindful of the added weight and maintenance requirements.

Using a body shop to fix the twist

If you're looking to enlist professional help to fix the twist in your aluminum Jon boat, a body shop is a great option. Here's a step-by-step guide on how to go about it:

Step 1: Find a Reputable Body Shop

Start by searching for local body shops that have experience working with aluminum boats. You can ask for recommendations from fellow boaters or marine mechanics, or look for shops that specialize in boat repairs.

Step 2: Consult with the Experts

Once you've found a few potential body shops, reach out to them and explain the issue. They may ask for photos or even come to inspect the boat themselves. Discuss the extent of the damage, the possible repair methods, and the costs involved.

Step 3: Agree on a Repair Plan

The professionals at the body shop will suggest the best approach to fix the twist. They may recommend drilling holes in the dented area, inserting wood braces, and using a come-along tool to pull out the dent, which should also help straighten the twist. They might also suggest using a frame machine to realign the boat's structure.

Step 4: Prepare the Boat

Before taking your boat to the body shop, you may need to prepare it for repair. This could involve cleaning the boat, removing any accessories or hardware that might interfere with the repair process, and documenting the damage with photos.

Step 5: Drop Off the Boat

Transport your boat to the body shop, ensuring it is securely loaded and won't sustain further damage during transportation. Provide the shop with any specific instructions or requests, and be sure to get an estimate of the repair time.

Step 6: Monitor the Repair Process

Stay in communication with the body shop during the repair process. They may have questions or need your input on certain decisions. Ask for progress updates and, if possible, visit the shop to see the repairs being done.

Step 7: Pick Up Your Boat

Once the repairs are complete, arrange to pick up your boat. Inspect the work done and ensure that the twist has been successfully removed. Ask the body shop about any special care or maintenance required after the repairs.

Step 8: Test the Boat

After retrieving your boat, test it on the water to ensure it handles correctly and that the twist has been completely eliminated. If any issues persist, don't hesitate to contact the body shop for further advice or adjustments.

Remember, the key to a successful repair is finding experienced professionals who understand the unique challenges of working with aluminum boats. By following these steps, you can rest assured that your Jon boat will be back to its original shape and ready for many more adventures.

Frequently asked questions