re-attaching aluminum helm to aluminum hull question

[Panhead Jim]

This is a new-to-me 1980 Terry bass boat, hull and structural all aluminum. The aluminum helm was originally pop-riveted to the interior aluminum side panel, which is of course ridiculously thin. The helm anchors in the floor are fine, screwed into the wooden deck, but ALL of the pop-rivets attaching the helm to the side panel have pulled all the way out. I'm a pretty good aluminum welder, but this side panel material is just too thin for me to have any confidence in my ability to weld to it, especially in a fillet. AND the helm and side panels are of different thicknesses, so anyone out there with welding experience knows that trouble also. Question, of course, is how would you re-attach the helm to the side panel? I thought about new pop-rivets and/or screws, and I don't really like either option. It's all completely blind, meaning no access for back-side fasteners, so that's obviously why they did it that way to begin with. Any suggestions?
Thank you!
Jim

 

[Pmccraney]

Re: re-attaching aluminum helm to aluminum hull question

I think most folks just re-attach with pop rivets... That's how mine were attached and they were in there nice and snug...

I know nothing about welding (particularly aluminum), but given your concerns there, I would just rivet them back on there and go boating

 

[64osby]

Re: re-attaching aluminum helm to aluminum hull question

I'll agree with rivets too. You might look at placing some backer plates on both side to give it some stability and structure if your worried about the rivets ripping out again.

 

[jbcurt00]

Re: re-attaching aluminum helm to aluminum hull question

Pix would help greatly, but if the helm has pulled away from the side panel, is there room to add a slightly thicker aluminum backers to both the helm & the side panel, clamp it all together, and pop rivet thru all 4 pcs of aluminum? Trying to avoid the areas around the previous rivets?

What do you think contributed to the rivets pulling thru & the console away?

Soft deck allowed the helm to sag inward?

Running too fast for conditions & pounding the boat thru waves/wakes?

Might address any of those concerns too.....

As PMC said: rivet & go :fish2:

 

[minuteman62-64]

Re: re-attaching aluminum helm to aluminum hull question

Take a look at the Grainger site. There are a number of types of "blind" rivets - particularly those that "mushroon" way out - that might be better than the garden variety of pop rivet. The interior of my hull has some panels attached with blind rivets that have a bigger diameter head than the Ace Hardware variety and also mushroon out at least 1/2 inch on the blind side. Can't remember what they are called, but I've seen pics on the Grainger site.

 

[Panhead Jim]

Re: re-attaching aluminum helm to aluminum hull question

Thank you, everyone. I've discovered a whole new realm of blind fasteners out there, now just have to choose the one I like best. I'm leaning toward some version of the rivnut style that is appropriate for aluminum and not too, too expensive. Problem with backing is I can't get there without removing the side panel, which is also riveted in place, but with real rivets. And I've already addressed the issues noted above that caused the problem - I've rescued the boat from the previous owner!!
Thanks, all.
Jim

 

[64osby]

Re: re-attaching aluminum helm to aluminum hull question

In years past I messed with a lot of rivnuts. The tool will be a little expensive for the limited use. Also they have a tendency to be a one or two time use and will spin quite often. I would try and put a dab of JB Weld or like product on them when installing to try and get a more permanent attachment. My .02