Repairing a Gash in a riveted aluminum hull

[sschefer]

Hi folks, I've been overthinking this to the max and have called at least a dozen shops. Some say no problem just weld it but the most reputable shop say's the best thing to do is bang it out and patch it. Well, if banging it out and patching it is the best thing, I can do that myself. The advantage I have is that this gash is directly under a stringer and when it's bolted back in with 3/16 (#10) truss head stainless machine screws it will be tied together nicely. My plan is to grind out the rip to relieve the tension caused by the extrusion of the metal and then make an outer and inner patch from .050 aluminum sheet metal.

Before I put the patch on I need to add a filler. The filler will be tied from inside to outside via the ground out crack (1/8" after grinding) which will form a H type connection. Once the filler is hardened, I'll put a layer of Gluvit down on both sides and then put the patches on while the Gluvit is still wet. The inside patch will also have the stringer on top of it and the Machine screws will go through the outsite patch, the hull, the inside patch and the stringer with nylock nuts and washers on the stringer. The patches will get and exterior coat of gluvit feathered out about 4 inches all the way around and then the stringer will be laid in.

Does that sound like a sane idea?

Here's a couple of pic's of the gash. Yeah, I know, looks pretty nasty. The boat is an Insurance company total but mostly because of the amount of work it took to get it to a repairable state. Lot's of labor stripping this thing out and checking every nook and cranny. I was going to pay myself but I realized I was broke. Maybe I'll jump in the Jet and take a trip to Washington. Maybe I can get in on some of that bail out money. LOL..

Here's a relative perspective:

Let me know what ya'll think.

Thanks

Steve

 

[oops!]

Re: Repairing a Gash in a riveted aluminum hull

one of the things about boat repair/building.....is....its really easy to get anal about things.

we all want to fix it the bes way we can....on fiberglass 12 foot boats we want to use epoxy with carbon fiber reinforced with kevelar.....then triple the floatation foam and add a deck that is a composite so it wont rot.....

and thats just the dingy we use to row to our 14 footers !


bang it out....weld it and splash some gluvit over....and go fishing

 

[Nova II 260]

Re: Repairing a Gash in a riveted aluminum hull

bang it out....weld it and splash some gluvit over....and go fishing

Yep, my thoughts also. Lay some of this stuff in if it's too bad and still won't seal. Available at welding supply houses and fastenall

 

[tashasdaddy]

Re: Repairing a Gash in a riveted aluminum hull

yep, get it as straight as you can, weld it up. get someone who welds aluminum, as it is totally different process.

 

[Bondo]

Re: Repairing a Gash in a riveted aluminum hull

I've been overthinking this to the max

Ayuh,.... I absolutely Agree....

 

[sschefer]

Re: Repairing a Gash in a riveted aluminum hull

Thank folks... Yep, I'm all for welding it as the best solution too! The patch is probably stronger in the long run but it's also ugly. Welded from the inside and filled with Lab Metal on the outside seems like the best solution to me also.

If you look closely you can see the riveted seams are a good 18" away from any welding. They will still need to be covered with wet rags because of aluminum's heat transfer characteristics. I don't want the mastic melting out of them. They will still get a coat of GluVit just to be on the safe side.

 

[sschefer]

Re: Repairing a Gash in a riveted aluminum hull

yep, get it as straight as you can, weld it up. get someone who welds aluminum, as it is totally different process.

I weld aluminum (stick, spool and tig). I used to be good enough to weld vertical and overhead but I haven't done that in a while, (it hurts too much.).

I'm going to have a shop do this since I don't want to hear my friends tell me what crappy welder I am when it leaks. Its far better to have someone else to blame when your boat is sinking. LOL...

 

[Nova II 260]

Re: Repairing a Gash in a riveted aluminum hull

.....The patch is probably stronger in the long run but it's also ugly........

Do you think the fish will see that patch and laugh at ya?

BTW, How did that happen?

 

[sschefer]

Re: Repairing a Gash in a riveted aluminum hull

Do you think the fish will see that patch and laugh at ya?

BTW, How did that happen?

Well, I don't think the fish would mind too much. I would though and it's my boat not the fishes, (yet).

As for what happened.. Rumour has it that the guy was up at Clear Lake, Ca fishing Rattle Snake Island and stuck it on the rocks. Pretty easy to do even if you know that island. The rocks are mostly Volcanic and razor sharp. My brother bought it from the guy that put it on the rocks and paid the equivalant of the deductable on the guys insurance, (2500.00). It's a 91 MonArk Legend 1800 FS with a 91 Belgum made Mariner 100 (merc 115). Shortly after he bought it he realized he had too many other projects to do so I bought it from him for the same price. It's on a fairly new EZ Loader trailer with new rubber and bearings and the motor was completely gone through a year ago.

I stripped it down to tin only so I could check everything thoroughly. It's actually in pretty good shape but the craftsmanship was a bit lacking in several areas. I'm rebuilding it from the bare hull up and I'll take the time to do it right. The boat should last me long enough to save up for the North River that I really want.