first boat 14ft.lonestar aluminum repair

[dombarb]

purchased my 1960 lonestar, has not regeistered since 1966.must have had water in the bow. Three of the u shaped stiffners are rotted and I missed the fact that the aluminum in this area is deeplly pitted adjacent to the stiffners.I am new to aluminum repair and would appreciate advice on how to properly do the repair.specifically 1) after removing the stiffners I paln to use them as models and have new ones fabricated Out of 0.063 alum. sheet stock 2) Should I cut out the old pitted alum. or can I rivit in a new patch panel over the old floor working from the inside? 3) Are 1/4" solid rivits adequate or will it be necessary to aluminum weld the seam areas of the patch. The pitted area is approx.30"by36". I plan to extend the patch well beyond the deeply pitted area. 4) the remainder of the boat is in good shape.Would I be advisable to grind and expose the pitted area were two holes are and alumumin braze that area. your experience and reccommendations are appreciated. thanks Dom Costabile

 

[Bob_VT]

Re: first boat 14ft.lonestar aluminum repair

Pictures??

Moving to restoration sounds like a great project

 

[dombarb]

Re: first boat 14ft.lonestar aluminum repair

Thanks for the reply Rob Vt. I snapped some photos however I can't figure out how to shrik them to a web size. I will elicit my neplhews expetise in the AM. thanks again. Dom

 

[Bob_VT]

Re: first boat 14ft.lonestar aluminum repair

There is a tutorial on the Non boating section the top 3 posts http://forums.iboats.com/forumdisplay.php?f=32

 

[dombarb]

Re: first boat 14ft.lonestar aluminum repair

Wow it did it! Note the deep pitts in the floring. thanks again Dom Costbile

 

[Bob_VT]

Re: first boat 14ft.lonestar aluminum repair

That is severe and will have to be stopped. Where the pitting is on the flat surfaces..... that will be a fairly easy fix. The braces that have been eaten away will present an additional challenge.

Fo the flat surfaces...... lightly sand, wipe down with vinegar and apply gluvit (probably 2-3 coats). As far as the molded strips..... I am afraid you are going to have some pieces manufactured to do the repairs and once again use gluvit.

 

[Bob_VT]

Re: first boat 14ft.lonestar aluminum repair

If you want to install "patch panels" I would rivet them right over the old from the inside and use the gluvit as a glue along with rivets. Haveing new strips made to replace the old ones can be done two ways. You can have new ones mad to overlap/cover the old ones or replace the old ones.

Gluvit is an epoxy made by marine tex. It "creeps" and flows into cracks and gaps to seal up the hull. The best part is that it was delevoped to withstand flexing w/o cracking. The only downside is that it is not good if left in sunlight unless it is then covered or painted since it does not react well to UV rays. http://www.marinetex.com/gluvit.html

 

[rirory]

Re: first boat 14ft.lonestar aluminum repair

I had a similar problem with my project boat---also a lonestar---you can look up my pictures. I went to a machine shop and had some channels with wings (called high hats) made---you can then have anyone who uses an air rivet system, rivet them in place right over the old ones. Just make sure the wings extend 3/4" past the old ones. Then use glu-vit or steel-flex over the whole area. Also if there are pin holes, A rivet and glu-vit will seal the holes.----good luck-----

 

[dombarb]

Re: first boat 14ft.lonestar aluminum repair

Thanks bob VT and rirory for sharing your experiences. I feel better with the advice you have shared with me. I will post some pictures of the project as I go. appreciate your suggestions. Dom Costabile