Durafix project (completed)

[Redeyedwiggler]

I found this product..

http://durafix.com/index.html
I placed an order today and wanted to share my repair project so that others can form an opinion about this product with me..
I'm no pro and this will be my first attempt at fixing an extremely damaged aluminum boat.
***edit***
Durafix was a bust on this project.. I find that the product works well on level surfaces only.
this thread is dead from here on out.
see last post for my finished boat project!

 

[Redeyedwiggler]

Re: Durafix project

Re: Durafix project

and these photos are the beginning to my duck beater

 

[Redeyedwiggler]

Re: Durafix project

Re: Durafix project

After hammering out most of the dents and shaping the cracks to move the gaps closer together I've polished the cracks with a dewalt wire brush on my grinder.
I'm amazed at how well the grinder with the wire brush handles the aluminum, nice polished and clean (paint free) area to start my welds.
I'll need to edit up some photos to finish this project here.. also this is day one with the boat and I don't have the Durafix yet. Ordered but not here.. so for now it's all just prep work.

 

[Redeyedwiggler]

Re: Durafix project

Re: Durafix project

ok I removed the wood from the transom because it was so soft I could poke my finger into it and I also repaired the bung hole.
The tools I am using are as follows:
1 regular claw hammer
1 ball peen hammer
1 rubber mallet
1 small steel anvil
1 angle grinder with a steel brush attachment and a sanding attachment, also a few cut off and grind wheels.
as you can see I chose to fix one really delapitated aluminum boat. The bow plate re-enforcement is totally cracked through and spread apart a few inches at the largest gap. If this product is nearly as good as the add shows it to be.. I'll be Fishing and hunting in no time! I have faith.. so,we'll see!

 

[Redeyedwiggler]

Re: Durafix project

Re: Durafix project

The tools and more inside hull photos.
I'll also start to number the holes and cracks to make the project a little easier to follow.

 

[Redeyedwiggler]

Re: Durafix project

Re: Durafix project

updated photos holes are now numbered to help identify before pics and after.
cracks are also measured.
crack 4 and 6 on the inside of the hull are in actuality the same crack, but look like two cracks from the inside.

 

[Redeyedwiggler]

Re: Durafix project

Re: Durafix project

more pics

 

[Redeyedwiggler]

Re: Durafix project

Re: Durafix project

I stitched the bow together to help with filling the crack. I used an old coat hanger as bailing wire.
crack 1 is around 3 inches long
crack 2 is 2 inches long
crack 3 is around 3 inches long
crack 5 is around 3 inches long
crack 6-4 is 21 inches long
crack 7 is 11 inches long
crack 8 is around 3 inches long
crack 9 is 10 inches long
crack 10 is 7 inches long
crack 11 has allot of cracks and vary in measurements so 12/3 inches longis sufficient for explanation.
crack 12 is 3 inches long
crack 13 is 14 inches long
crack 14 is 16 inches long
crack 15 is 20 inches long and is the most significant crack in the boat.
I spoke with Randy over at durafix today and my order should be here today or tomorrow.. I'll update time and energy updates from here then finish photos at the end of this thread.

 

[Redeyedwiggler]

Re: Durafix project

Re: Durafix project

ok here is the update.
Durafix on a large scale project works fine but is harder than it looks to work with! Preparation is everything! on a project of this size, regular propane torches
just won't cut it!
I went out and bought a mapp gas and oxy set up that worked great!
I thought that a larger torch was the way to go but then figured that the heat would melt the aluminum and I know now that the mapp gas system works best.
If durafix cools too fast it will turn brittle and crack, so you need to heat a much larger area on big projects so the aluminum mass won't suck the heat right away from the durafix weld. As the durafix cools it is necessary to help it cool slowly by keeping it warm with the torch and slowly removing the heat from the weld.
The strength of this stuff is amazing! I had some problems with gravity as this product doesn't like to be worked on anything but a level surface so I found myself grinding some of the large beads of excess that developed from trying to fill a gap against gravity.
The grinder absolutely had to work as though it was grinding steel.
My welds are gooey looking but the boat was never going to look "good" again.. It's my duck beater and function is everything! hopefully it stands up to the cold water and pounding or a rough lake!
pics to follow

 

[floatingwoody2006]

Re: Durafix project

Re: Durafix project

Hey man.. Glad to see you ended up with a duck boat finally. When i was repairing mine, the seam at the front was somewhat seperated as well. I ended up sealing all the seams with gluvit, and pouring what i didn't use into the front seperation. Took 2 solid days to cure, but stronger than new now. The guy's here pointed me to the gluvit, and it's awesome stuff. BTW..My brother ended up "lending me" his 6 horse yamaha, so my 3 horse gamefisher is available for sale.

 

[Redeyedwiggler]

Re: Durafix project

Re: Durafix project

Scott?
hey man, yeah this thing is a trip! oh well looks like gluvit and traditional mending is in order.
The durafix works wonders on small holes and would work well on the larger cracks if they were level. "level" being the key word.
The bond that durafix makes is awesome and extremely strong but then gravity on non level surfaces will suck the weld right out of the crack, the product won't fall through, rather it will slide down the surface and ball up at the most level area.
So when doing large cracks, like mine, the durafix just won't do because there is no way of leveling a bow or rounded hull.
I have re-enforced all welds with aluminum sheets for added strength.
The ribs came out great and I don't expect any trouble from them again, one or two more repairs and this thing will be ready for paint.

 

[floatingwoody2006]

Re: Durafix project

Re: Durafix project

Just having gone thru much of the same, i sympathize with you. I didn't have the long gashes or the extent of seperation you had there though. Sounds like your givin er hell..How satisfied will you be when you catch the first bass, or get the duck in that thing? I know the durafix video makes it look simple as pie, but others on this forum had said it's no where near that simple. After your posting, it seems confirmed. If you need any help, let me know. Also.. I bought a trailer with an older glass boat on it just to keep the trailer. If you want the boat it's yours. It does need floors and a glass patch up front. Pm Me if you want to take a look before it goes dumpward this weekend.

 

[Redeyedwiggler]

Re: Durafix project

Re: Durafix project

I think I'll name it... Patches! or "It May Be Ugly, But it doesn't leak"

So yeah I'll try to make it by before the weekend to take a look.. floors don't scare me but the need for a trailer does.. so I probably won't take it unless it's really small.

 

[Redeyedwiggler]

Re: Durafix project (completed)

Finished with the patches and the paint.. the motor is almost done and then I'll cammo the entire boat for ducks!
Worked out well for a free boat!!!