Cut Aluminum Transom, How Do I Fix This? (pics)

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fishrdan

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Hey guys, I have a cut in the cap and top section of my 01 Crestliner's transom, results of thieves trying to cut out the drive. I want this welded up, but don't know if this can be welded with the plywood transom still in place. I was thinking of backing the cut with 1/16" aluminum plate and then having the cut welded up, but don't know if a welder will touch this since they will be welding on top of wood. I've never welded aluminum, but know if it was steel it would be a big flaming mess :eek: The cap is about 2 1/2" wide and cut going down the transom is about 3-4".

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If this can't be welded up with the plywood transom in place I would like to find another way to repair the cut; epoxy, fiberglass, DuraFix, 5200, ??? What do you think will fill the cut and not pop back out again or crack, anything? This is an I/O boat so it won't have as much stress on the transom's top as an outboard boat.

If I have to remove the plywood to weld it up, I'll need to completely remove the beige colored cap (which is welded in place), remove the transom plywood, weld up the cut, weld the cap back together, re-install the plywood and then weld the cap back in place. It's going to be a royal PITA to remove the plywood so I'm trying to figure out how to get it done without removing the transom plywood.

thoughts and suggestions?
 
Docknocker

Docknocker

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Re: Cut Aluminum Transom, How Do I Fix This? (pics)

Wow! I don't have any repair suggestions, I'm just wondering what kind of bonehead thought he would pull THAT off!! What a moron - why wouldn't he just steal the whole boat?? You poor guy. Best of luck with the repairs...
 
F

fishrdan

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Re: Cut Aluminum Transom, How Do I Fix This? (pics)

This is a theft recovery boat that I'm rebuilding. As far as I can tell, they couldn't figure out how to get the transom assembly loose and started to cut it out, but gave up for some reason.

I got the boat off Ebay and the seller "forgot" to mention that there was a huge cut in the transom. Really of pizzed me off when I picked up the boat (live and learn), but all in all its working out pretty well.
 
Docknocker

Docknocker

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Re: Cut Aluminum Transom, How Do I Fix This? (pics)

I would guess a skilled aluminum welder could do it, as I think the temp. required to weld aluminum is relatively low. I've seen welders use a wet towel as a heat sink adjacent to the repair, to prevent heat damage or warping of areas close to the repair area.
 
J

jonesg

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Re: Cut Aluminum Transom, How Do I Fix This? (pics)

I think a tig welder could do that , they weld coke cans for fun.
 
Bondo

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Re: Cut Aluminum Transom, How Do I Fix This? (pics)

Ayuh,....

While it wouldn't be all that Easy,...

I know I could weld that up with my Mig welder...
Short welds, done slowly, with wet rags,+ plenty of water....

It might singe the wood,+ smoke abit, but that's all...
 
F

fishrdan

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Re: Cut Aluminum Transom, How Do I Fix This? (pics)

My buddy's MIG welder is broken, so I'm at the mercy of a welding shop to get this done if going that route.

I like the simplicity of DuraFix, but have heard it can be problematic trying to lay it down on a vertical surface,,, likes to run off. Could just be a heat control issue though?
 
D

D.spencer

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Re: Cut Aluminum Transom, How Do I Fix This? (pics)

Even if you weld up the transom, you will still need to replace the plywood in the transom because it is cut and has been weakened (IMHO). Seems to me that it would be first priority to remove the wood so that a chill bar can be clamped to the inside and then mig welded/tig welded up. If I was doing it, I would use my spool gun as tig welding is so tedious for something like that.
 
F

fishrdan

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Re: Cut Aluminum Transom, How Do I Fix This? (pics)

The cut is on a 45* angle so I doubt much strength has been lost. If this boat had an outboard I'd be concerned with the cut causing flex at the top of the transom, but since it's an I/O I don't see how it's going to make that much of a difference. I did filled the plywood cut with epoxy/sawdust just to make sure though.

I bent a 2 1/2" wide, 1/16" piece of aluminum that backs the cut so it's ready for what ever I decide. Also picked up DuraFix rods (Harbor Freight equivalent anyways) and still sitting on the fence whether I want to use the Durafix or have it welded. I'm going to play around with the DuraFix on some scraps to see how well it works on a vertical part

I'm thinking the downside to Durafix is I'll have to clear a bigger section of of paint off the aluminum before "braizing" opposed to welding, probably 8-12" all around for the DuraFix and 3-4" for welding,,, sound appropriate? And, Durafix is supposed to be much harder than aluminum, so grinding/filing/sanding the Durafix would be mode difficult than if it were aluminum fill.
 
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DaveHawkins

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Sep 25, 2007
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Re: Cut Aluminum Transom, How Do I Fix This? (pics)

I have experimented a little bit with the aluminum brazing rod. The little bit that I used, I found it works really well on clean, thin, aluminum sheet, that is positioned on a horizontal plane. The thicker the aluminum, the harder it is to get enough heat with a basic propane torch to get the rod work properly. I think probably MAP gas or an acetylene torch would work fine for thicker aluminum.

I tried to weld a couple of transducer holes at the transom on my aluminum v-hull. I was able to get the aluminum hot enough to get the rod to run, but found it very difficult to do a nice build up on a vertical surface. I ended up cutting a small aluminum patch and bonding it with 5200, and one stainless screw and locknut.
 
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