Repairing holes in Aluminium

[nearpar]

I just purchased a Starcraft Islander that has some holes where there were once mounts, lights and a horn. I would like to some how patch these up and paint over them to make look they were never there. What can I use and what proceedure to follow. Holes range from about 1 inch to 1/4 inch in size.:facepalm:

Thank you in advance.

 

[boatguy94]

Re: Repairing holes in Aluminium

Welcome to the Starcraft club! Have you put up any pictures yet? Ohh and another Michigan guy !

I filled in a couple big holes in my transom with some thin aluminium, and then put some JB Weld on them. I just got enough on it at first to get the aluminium to stick, then I went back and filled up the rest with more JB.

I'm sure other's will supply more ways of doing this, but thought I'd give you my way I did it.

 

[jasoutside]

Re: Repairing holes in Aluminium

Hey another MI fella with a Starcraft, awesome!

And...

I'm seeing this isn't your only one either, cool!

Lets see some shots of that aluminum trouble you are having, and as long as you are at it, the rest of the rig too

 

[nearpar]

Re: Repairing holes in Aluminium

Yes I now have 2 starcrafts ! My newest is a 22 ft Islander and my other one is a 18 ft hl-180 runabout with a 80hp Johnson. I will take some pics later today and post...

 

[nearpar]

Ok here are the pics, New 3/4 floor. new transom, etc...

 

[nearpar]

Re: Repairing holes in Aluminium

Ok now for the holes I need to repair.... Holes are in the winshield area and I can get to both sides of the holes. Also holes in transom, plus misc screw holes here and there can't get to both sides of those.

 

[jasoutside]

Re: Repairing holes in Aluminium

Cool, she sure looks familiar!

I ran JB Weld on all my holes like that. Mine have yet to be sanded down and get the test of time so I can't fist hand, long term durability.

Awesome!

 

[fishrdan]

Re: Repairing holes in Aluminium

The only way to make it 100% perfect is to weld it up then sand it smooth. I did the JB weld thing on my boat and it looked perfect for a season, then it cracked. I'm kicking myself for not having it welded. Aluminum and JB weld have different expansion rates and an edge bond will eventually pull free. If you just needed to seal up some holes the JB would probably work OK with a backing plate, but it sounds like you want to paint over the repair and have it look perfect

One solution would be to install rivets in the holes, to match the existing rivets. They make large head rivets (1/2"?) that would cover most of those holes. Make some backer washers, apply 5200 to the washer and rivet, rivet it down, clean up the excess 5200. This wouldn't be the cleanest solution though...

It looks like most of you repairs need to be done behind the windshield, how about covering the entire area with something like a sheet of Starboard, Nautolex vinyl, etc.

For the mis-mounted kicker bracket, I think the easiest solution would be to install a couple SS carriage bolts sealed up with 5200

 

[nearpar]

Re: Repairing holes in Aluminium

The only way to make it 100% perfect is to weld it up then sand it smooth. I did the JB weld thing on my boat and it looked perfect for a season, then it cracked. I'm kicking myself for not having it welded. Aluminum and JB weld have different expansion rates and an edge bond will eventually pull free. If you just needed to seal up some holes the JB would probably work OK with a backing plate, but it sounds like you want to paint over the repair and have it look perfect

One solution would be to install rivets in the holes, to match the existing rivets. They make large head rivets (1/2"?) that would cover most of those holes. Make some backer washers, apply 5200 to the washer and rivet, rivet it down, clean up the excess 5200. This wouldn't be the cleanest solution though...

It looks like most of you repairs need to be done behind the windshield, how about covering the entire area with something like a sheet of Starboard, Nautolex vinyl, etc.

For the mis-mounted kicker bracket, I think the easiest solution would be to install a couple SS carriage bolts sealed up with 5200

Yes that is exactly what I am going to do the winshield will be patched up with some rivits and the just carpet. As for the other holes SS carriage bolts are a good idea...BTW what is 5200 ?

Thank you

 

[markandclark]

Re: Repairing holes in Aluminium

5200 is 3m marine adhesive sealant 5200 google it

 

[sschefer]

Re: Repairing holes in Aluminium

Do not weld that..It's just going to crack on you. Clean it up, put some masking tape on the back side and use jbweld. When it hardens, just sand it down, prime and paint. I've done it this way many times and I'm also an accomplished TIG, MIG and Stick welder. If there was a safe way to weld thin 6061-T6 aluminium that's aged and stressed I would have done it. Starcraft knows you don't weld it and that's why these boats are riveted.

6061 looses 1/2 it's strength when it's welded. It will also shrink and warp badly unless you are extremely familiar with the process.

 

[nearpar]

Re: Repairing holes in Aluminium

Thank you that makes perfect sense....

 

[ezmobee]

Re: Repairing holes in Aluminium

I have also experienced some JB Weld repairs "pop" after time on my last boat. On my current one, I used some little squares of aluminum flashing and splooged it in there from the back side. So far so good. Very nice Islander you have there.

 

[boatnut74]

Re: Repairing holes in Aluminium

Nice Islander you got there. Another solution would be marine tex. I think its a little more flexible than JB is. A few people have used it on there rebuilds with success. Its sandable and paintable.

 

[Art Bernard]

Re: Repairing holes in Aluminium

Yeah, 6061 alum is a B%$^h to weld after stress and exposure, go with the backing plate, jb weld and sand smooth, than put a nice dash pad over it.

Art

 

[kfa4303]

Re: Repairing holes in Aluminium

I've had luck with JB weld too, but it could always come undone, depending on how much flex in the aluminum and change in temps you experience. If the holes are above the water line you can probably get away with just JB. However, if they're some below the water line, you may also want to try using stainless steel bolts with an oversized washers on either side of the hole along with JB weld to fill/plug the holes. Not the most attractive fix, but certainly durable. I would try JB alone, see if it works, if not then you can do more as needed. Good luck.

 

[nearpar]

Re: Repairing holes in Aluminium

Thank you for all the great replies, I plan on using Marine Tex or JB weld on the holes in the dashboard area. I will sand and give it a coat of paint, follow up with a piece of Luan coated in marine epoxy and then covered with a nice marine carpet to match the interior.
As for holes in the transom etc. I will use stainless carrage bolts.