large dent in aluminum hull...what would you do?

[Drindin]

I was given this boat so how this happened, I don't know. The dent in the picture was repaired with some type of epoxy, etc. Obviously, the boat was taking on water after whoever messed up. Anyways, the epoxy was dripping as it hardened, leaving little stalagmites everywhere. When I picked up the boat, I had to put it in the water and use a trolling motor to get around to the neighborhood boat ramp (I havent been able to run it with an outboard yet, so I don't if the steering is ok). The boat showed no leaks...the trip took about 30 mins. A friend said he would bondo over it, i thought about a piece of aluminum and trying to bend/shape it and rivet it into place(look close to original), or what about getting a tig welder to cut out the area and weld new. I don't know where to start...what would you do?

 

[BigB9000]

Re: large dent in aluminum hull...what would you do?

you could get inside and try kicking it out.

....for free I would leave it. maybe get some Henrys Roofing Tar, some metal plating, and a rivet gun (I have done it before)
It'll look like crap, but might work. Chances are the boat will never have a resale value.... even in its current condition.

 

[Bob_VT]

Re: large dent in aluminum hull...what would you do?

I would bring it to a skilled welder and have a new piece of aluminum added........ I doubt that kicking that will work!

 

[Utahboatnut]

Re: large dent in aluminum hull...what would you do?

You may be able to use a dent puller and some plates on the inside to spread the load out. Just a bolt or screw wont have the holding power and will just rip thru but if it had some steel backing behind it may work. If the inside is accessable, a single jack, body hammers and dollies might work as well. That would be a mighty big chunk of bondo, not that it couldn't be done just would be alot. If you could pound it out somewhat then the bondo might be used to return the lines of the boat. I would think you would pay a pretty penny to have a piece custom made and welded in by someone that knows what they are doing.

 

[funk6294]

Re: large dent in aluminum hull...what would you do?

I think I am with Utah here... You could use a combination of a dent puller, BF Hammer, and then you may be able to use a hammer and dolly to help smooth things out then hit it with some marine tex to bring the lines back.

 

[lncoop]

Re: large dent in aluminum hull...what would you do?

I would think you would pay a pretty penny to have a piece custom made and welded in by someone that knows what they are doing.

You might be surprised. It may turn out not to be as much as one would think. Also, if you did have it done you might consider asking him to do the welding and let you do the finish work. I'm sure you could handle that part and doing it yourself would save you some considerable cash. Look at it this way. The boat was free. It sounds like you have it in running condition, so why not spend a few bucks to make it seaworthy rather than wondering whether that home made patch job will hold. I'm the king of cold weld patching, but I think given the size and location of the patch welding is the only way.

 

[Jeep Man]

Re: large dent in aluminum hull...what would you do?

Treat it like the rear quarter panel on the old '72 Buick. Bodymen did this kind of repair everyday until after market parts made it easier. If you don't want to take it on, a local body shop could pound it out for a price.

 

[jspano]

Re: large dent in aluminum hull...what would you do?

i'm with the auto body type of pulling it out drill some holes, place some structure inside and pull it out. then some auto body type hammering dolly on 1 side hammer the other. do the best you can with the orginal alum, water test and use gluvits on the inside. if needed or just wanted fab some alum and sandwhich 5200 and closed end rivets or ss bolts

if you can get it sea worthy without any navigational problems the fish will never know the difference

 

[jmzhbz]

Re: large dent in aluminum hull...what would you do?

Start in the center of dent and heat outwards from it with a torch until it flexes somewhat... Be careful not to get it too hot...or you will blow a hole in it. Then you should be able to slowly work it out with a rounded metal plate. Let the area cool and inspect.. Continue to work your way to the outer edges. Do a little at a time and it will come out.. I used to have to do that all the time to the aluminum stock tanks we had on the farm when I was growing up. We had some that were galvinized steel (which I will not heat up to this day due to fumes!!) and some were aluminum.. If you are careful and watch what you are doing, it will be easy.. but time consuming. Otherwise, have a piece cut and welded in..

Hope this helps a bit.

 

[Drindin]

Re: large dent in aluminum hull...what would you do?

I appreciate the replies! My problem is I have absolutely no experience with body work. I may be wrong, but it seems like using a dent puller and hammer would be ALOT of work. Whatever epoxy-like patcher they used would have to be removed(how?) and then, and only then, would I see the magnitude of damage that was done.I would have to pull up the flooring just to get @ the backside and something tells me I would be stretching my luck. I really like the idea of having someone cut out the bad area and weld a new piece of aluminum in it's place. Any ideas where I would begin my search for someone that can do it? Body shops? Sheet Metal fab shop? What should I look for, or how can I tell the caliber of a welder?

 

[xxlurchxx]

Re: large dent in aluminum hull...what would you do?

Dude basstrackers are nice little boats, I would say your decks are toast anyway. You looking at a couple hundred bucks worth of plywood and some outdoor carpetting to get it done. The aluminum is pretty pliable and you should be able to work the dent out. You can use a grinder to remove the splooge on the outside. It's really a matter of whether or not you want to take on a project or not. Search Basstracker Pro 16 for a remake of one of these.

 

[lncoop]

Re: large dent in aluminum hull...what would you do?

I appreciate the replies! My problem is I have absolutely no experience with body work. I may be wrong, but it seems like using a dent puller and hammer would be ALOT of work. Whatever epoxy-like patcher they used would have to be removed(how?) and then, and only then, would I see the magnitude of damage that was done.I would have to pull up the flooring just to get @ the backside and something tells me I would be stretching my luck. I really like the idea of having someone cut out the bad area and weld a new piece of aluminum in it's place. Any ideas where I would begin my search for someone that can do it? Body shops? Sheet Metal fab shop? What should I look for, or how can I tell the caliber of a welder?

Start by calling a local marine shop. If there is one you trade with already so much the better. Most of them either have a welder in house or have one local they send their welding jobs to. At the very least they will be able to recommend someone.

 

[MichaelP]

Re: large dent in aluminum hull...what would you do?

My 16 Starcraft had some mean dents above and below the water line. I first took it to a body shop and told them to do what they could for $100. Then drilled holes and made releaf cuts with a jig saw and did more hammering. Welded 1/8 alum plate all around inside and over the holes and slots on outside. Faired it out with a flexible epoxy (well prepped). After 3 years of occational heavy use there have been no problems.