Best Aluminum Boat Patch Kits: Quick And Easy Fixes

Aluminum boat repair kits are used to fix common issues with aluminum boats and canoes, such as leaking seams and rivets. The repair kits typically contain epoxy resin, a hardener, filler, mixing tools, and protective gloves. Some kits also include alcohol cleaning pads and repair instructions. When choosing a repair kit, it is important to consider the size of the repair area and the flexibility needed for the specific application. For example, G/flex epoxy is known for its flexibility and ability to bond with various materials, making it a popular choice for boat repairs.

Best products for an aluminium boat patch kit

When it comes to aluminium boat patch kits, there are a variety of products available that can help you get back on the water in no time. Here are some of the best options to consider for effective and long-lasting repairs:

Epoxy Putty and Adhesives

Epoxy putties and adhesives are among the most popular choices for patching aluminium boats. These products offer a permanent solution for various types of repairs. Here are some highly-rated options:

• Marine Epoxy by J-B Weld: This marine epoxy is designed specifically for underwater repairs and can be used to fix leaks in boat hulls, decks, and other components.
• H-450 Alumbond Aluminium Putty Repair Kit: This kit provides a strong and durable repair solution for aluminium boats. It includes everything you need to mix and apply the putty effectively.
• WEST SYSTEM G/flex Epoxy: This flexible epoxy is ideal for repairing leaking seams and rivets in aluminium boats. It can also be used on other materials such as fiberglass, wood, plastics, and metals.
• TotalBoat Aluminium Boat Leak Sealer: This sealer is specifically formulated to stop leaks in aluminium boats. It provides a fast and effective solution to get your boat back in the water.

Welding Solutions

Welding is another effective method for patching aluminium boats. While it may require more specialised equipment and skills, it can create strong and long-lasting repairs. Consider the following products:

• Aluminium Brazing Rods: These rods are designed for use with a propane torch and provide a simple solution for aluminium repairs. They are ideal for filling in small holes and cracks.
• Leisure Time 60009 Aluminium Patch Kit: This patch kit offers a convenient way to repair tears and holes in aluminium boats. It includes self-adhesive patches that can be applied directly to the damaged area.

Fibreglass Repair Kits

Fibreglass repair kits can also be used to patch aluminium boats. These kits often include fillers and adhesives that can be used to fill in cracks, holes, and other types of damage:

• Marine Fibreglass Repair Kit: This kit is suitable for repairing holes, chips, and cracks in boats. It includes a gel coat repair compound that can be used on fibreglass, aluminium, and other materials.
• TotalBoat Polyester Structural Repair Putty: This marine-grade repair putty is ideal for filling in larger holes and cracks in aluminium boats. It is easy to use and provides a strong and durable repair solution.

Remember to carefully assess the damage to your boat and choose the most suitable product for your needs. Always follow the instructions provided with the product to ensure safe and effective repairs.

Fixing cracks in an aluminium boat

To fix cracks in an aluminium boat, you can either weld the crack or use an epoxy putty or sealant to fill and seal it.

Welding

Welding is a permanent solution for fixing cracks in an aluminium boat. It involves using a welding machine to melt and join the metal together. This method is best performed by a professional welder and will cost around $50. Before welding, you need to clean the area around the crack with a wire wheel grinder to ensure a good weld.

Epoxy Putty and Sealant

If welding is not an option, you can use an epoxy putty or sealant to fill and seal the crack. This method may not last forever but can buy you a few more seasons before a permanent fix is required. Here are the steps to follow:

• Clean and prepare the surfaces inside and outside the crack. Remove any dirt, grease, or debris from the area to ensure the epoxy adheres properly.
• Apply a "snake" of epoxy putty along the crack, making it about 2 inches longer than the crack itself so that you have an inch of overhang on either side. You can use a two-part epoxy putty like JB Weld Marine Weld, which comes in a syringe for easy application.
• Smooth out the epoxy putty from the inside of the boat, pushing it into the crack and ensuring it oozes out the other side.
• Move to the outside of the boat and smooth out any epoxy that came through.
• Allow the epoxy to cure fully, following the manufacturer's instructions for curing time.
• Apply a second "snake" of epoxy putty on the outside of the crack and smooth it out.
• Once the second application has cured, sand the repaired area smooth.
• Prime and paint the repaired area to protect the epoxy and match the colour of your boat.

Aluminium Patch

In addition to epoxy putty or sealant, you can also use an aluminium patch for added strength. Cut a piece of aluminium to cover the crack and clean the area thoroughly. Apply a permanent sealer like 3M 5200 between the patch and the boat, then rivet the patch in place.

Repair Kits

There are also aluminium boat repair kits available that contain the necessary materials and instructions for fixing cracks and leaks. For example, the West System Aluminium Boat Repair Kit includes G/flex 650 Toughened Epoxy, adhesive filler, application syringes, mixing cups, mixing sticks, and protective gloves.

Using an aluminium sheet patch for a damaged boat

If your aluminium boat has a hole in it, you can use an aluminium sheet patch to repair it. This is a more permanent solution than using putty or filler, although it is more complex and time-consuming.

First, you will need to assess the damage to your boat. Take pictures of the hole from multiple angles, so you can better understand how best to repair it. If the hole is on the bottom of the hull, you will need to take the boat out of the water before beginning any repairs.

Next, you will need to gather your materials. As well as an aluminium sheet, you will need a permanent sealer, rivets, a hammer, and a drill. Ensure you have enough rivets to secure the patch in place – you may wish to use more rivets for larger holes. You should also wear protective gloves when handling the patch and other materials.

Before you begin, clean the area surrounding the hole and soften the edges of the aluminium with sandpaper. This will help the patch adhere to the boat more effectively. Cut the aluminium sheet to size, ensuring it overlaps with the hole by at least 2 inches. Drill stopper holes at the end of each tear to prevent crack propagation.

Now, apply the sealer to both the patch and the area surrounding the hole. Place the patch over the hole and secure it in place with the rivets. Use the hammer to gently tap the rivets into place, being careful not to apply too much pressure.

Finally, check that the patch is secure and allow the sealer to cure overnight. If necessary, apply a mixture of G/flex and 407 Low-Density Filler to create a smooth finish.

Fixing a hole in an aluminium boat

Welding

The best way to fix a hole in an aluminium boat is to take it to a welding shop and have a professional weld the hole shut with a TIG welder. This method will ensure the repair is long-lasting and secure.

Epoxy

If you can't afford welding, you can try using an epoxy putty to fill the hole. First, ensure the area is hammered flat to close the hole as much as possible. Then, sand or grind the area and clean it with an acetone solvent. Mix the two-part, marine-grade epoxy putty by rolling equal parts of A and B together until it is a uniform colour. Press and smooth the putty into the hole and the surrounding area, from both sides if possible. If the hole is a crack, you should drill small holes at each end of the crack to prevent it from spreading.

You can also use a product called G/flex Epoxy to repair the hole. First, shape and clean the metal by hammering out the torn aluminium or using an auto-body or bucking dolly to get the hull back to its original shape. Cut away any torn edges to help the aluminium lie flat and drill stopper holes at the end of each tear to reduce the chance of cracking. Softening the edges of the aluminium with 120-grit sandpaper and use a coarse bristle disc to remove paint from the inside and outside of the boat. Finally, abrade the surface with 80-grit sandpaper.

To make your patches, cut a single piece of #743 280g/m2 Episize Glass Fabric for the outside and three pieces, in diminishing sizes, for the inside. Allow for two inches of overlap around the hole to give your materials space to bond. Brush both surfaces of the boat with the G/flex Epoxy, working the adhesive into any scratches or dings. To prepare the patches for bonding, lay the pieces on plastic and wet them thoroughly with the G/flex. Apply the patches, first to the outside and then the inside of the boat, smoothing them into the thickened mixture and removing any trapped air with a squeegee. Leave the patches to cure overnight.

The next day, grind the edges of the patches to remove any roughness and apply a mixture of G/flex and 407 Low-Density Filler to the inside and outside of the patches to smooth the boat's exterior and provide better scuff resistance on the inside. Once the mixture has cured, apply a mix of G/flex and 503 Grey Pigment to help camouflage the repair.

Other Methods

Other methods for fixing a hole in an aluminium boat include using JB Weld, a product called Marine Tex, or a combination of fiberglass fibre and resin.

Best sealants for an aluminium boat

When it comes to repairing an aluminium boat, the most common problems are leaking seams and rivets. To fix these issues, you'll need a reliable sealant. Here are some of the best sealants for the job:

3M Marine Adhesive Sealant 5200

The 5200 by 3M is a commonly used sealant in the marine industry and has a good reputation. It is known for its strong adhesion to aluminium, which is critical for long-term success in sealing leaks. However, some users have noted that it can be finicky to use and may become brittle and crack if the aluminium flexes. It is also available in a fast-curing version, the 5200 Marine Fast Cure.

Amazing GOOP Marine

Amazing GOOP Marine is a sealant that has been praised for its toughness and elasticity. It has a higher breaking point than 5200 and performs better in tear tests. GOOP also has excellent adhesion to bare aluminium and is more shelf-stable, lasting indefinitely after initial use. Additionally, it flows well and settles into a smooth finish, making it ideal for sealing fine seams and rivet holes.

West System 650-K Aluminum Boat Repair Kit

This repair kit includes G/flex 650 Toughened Epoxy, an adhesive filler that is specifically designed for bonding aluminium. The kit comes with protective gloves, mixing cups, application syringes, and reusable mixing sticks. It also includes detailed instructions on how to repair leaking seams and rivets in aluminium boats.

J-B Weld MarineWeld Marine Epoxy

The J-B Weld MarineWeld Marine Epoxy is another option for sealing leaks in aluminium boats. It is a fast-curing epoxy that can be used for easy and permanent repairs even underwater.

TotalBoat Aluminum Boat Leak Sealer

TotalBoat offers a specialised product for sealing leaks in aluminium boats. Their leak sealer is designed to address common issues with aluminium boats and ensure a watertight seal.

When choosing a sealant for your aluminium boat, it's important to consider the flexibility and adhesion of the product. A good sealant should be able to withstand the stress of abrasion, jarring, and flexing that aluminium boats often experience. Additionally, pairing your sealant with a high-quality, flexible boat coating can further enhance the integrity of the seal and protect against future leaks.

Frequently asked questions