Transom cap replacement ideas

[BOYS & TOYS]

I had to replace a broken,corroded and cracked transom cap. Started with a 2" square edge tubing with 1/8" wall and split with band saw extra long. Measured the flat length and marked that on the center. Cut a paper to match the curved sections and then transfer that next.
Back to the band saw to cut out pieces. The tube was 6061 so it needs to be annealed before bending.

 

[BOYS & TOYS]

Next extra large filler pieces are cut and welded in. After welding a flap disk is used to smooth the shape. The long ends are cut off to match the transom angle.
The new thicker and stronger cap is riveted to the inside and outside transom aluminum.
Hopefully this will give some replacement ideas for anyone with this problem.

 

[SHSU]

Nice work!!!

Wish I had the ability to weld aluminum. Would have allowed a lot more customization plus saved me some $$$

SHSU