Leaky aluminum boat - epoxy weld?

[Steve Mahler]

I have a 15' starcraft closed bow, late 60s, which I bought on Ebay last fall with a very leaky hull. When purchased, it probably brought on a gallon a minute, maybe more....Examination of the bottom revealed a few dents where a gap between the keel and bottom.

Based on my reading here, I tried gluvit (expensive) followed by a cheaper rubber/tar sealer which I found a Lowes for $7/gallon.

As of my third water leak test (in my pond) I am down to just one persistent leak. I have heard rumor of some kind of epoxy welding technique for the bottom - with a propane torch. This could be an urban legend.....any tips?

I have the boat off the trailer, up high, so I can work on the bottom. Flipping is not a great option....

Thanks for any help

 

[Bob_VT]

Re: Leaky aluminum boat - epoxy weld?

Okay.... et me see if I have this straight

You have used gluvit and rubber stuff from lowes? And... flipping the boat over is not an option????

I doubt the "propane" welding will help. I imagine it may ignite the goo you have on the inside.

At the point you are at now you might as well roughen the area where ther known leaks are and coat it with 5200 and let it set up.

 

[erikgreen]

Re: Leaky aluminum boat - epoxy weld?

The "epoxy weld" you are talking about is probably the low-temperature zinc "welding" rods you can get for aluminum. There are a couple "as seen on TV" brands of it, but you can also get the Bernz-O-Matic type that are basically the same at many hardware stores.

It sounds like you're not wanting to actually get this welded, which is possible and might be cheaper anyway, so you could give these a try if you have a small hole to fill, although as mentioned the process will probably burn off the previous adhesives and leave you with a mess. The process is similar to soldering, and isn't terribly strong nor does it fill big gaps, but it will join aluminum with metal.

If it was me doing it, I'd clean the metal off completely, determine where the leaks actually were, replace rivets and metal as needed and/or pay to weld the hole shut.

You'll probably have better luck "fixing" the leaks if you don't mix adhesives... IE, clean everything off and start fresh with 5200 or whatever else you try. From the sound of things you have it down to a small leak now, but as the repair ages something else will let go and you'll be back to square one.

Erik

 

[iwombat]

Re: Leaky aluminum boat - epoxy weld?

I had the same issue with my starcraft resto project this winter. Here's what I did.

Remove all patching compounds and products.
Pound out the aluminum the best you can to the original shape using hammers and auto-body tools.
Replace rivets with closed-end blind rivets (or use pneumatic tools and the original style if you've got the means).
Gluvit all seams inside and out.


It doesn't leak a drop now.

 

[raidercoop]

Re: Leaky aluminum boat - epoxy weld?

I believe you may be talking about an epoxy rod that you push into or against the hole in your aluminium after you have taken a propane torch and heated it. I used this on a buddy's boat and it worked fine. It is real easy to work with, basically it melts like a crayon into the hole or void you are trying to fill then after about a day it becomes rock hard. Here is a link to to Cabelas website and the product that I used. Good Luck!

Raidercoop

Cabela's Aluminum Boat Patch Item: IH-010655

http://www.cabelas.com/cabelas/en/t...hall&Nty=1&Ntt=aluminum+boat+repair&noImage=0

 

[Willyclay]

Re: Leaky aluminum boat - epoxy weld?

I had good results with the Starbrite Epoxy that comes in a roll and looks like a grey cigar. You just cut off a piece and roll it in your hands to activate the catalyst. Used it on my 1965 LoneStar Medallion II as well as a few other things like refrigerators, A/C units, etc. Great for plugging holes and small repairs.

 

[Steve Mahler]

Re: Leaky aluminum boat - epoxy weld?

I appreciate your comments, and will look into these solutions. There are boats you restore for love, and then there are the other ones. I essentially got this hull for free (LOL) paying only for the motor. I have other hulls, and wanted to try some low cost options before scrapping it - which would be a shame. I got quotes on welding which were way too high for a low value hull, in this region of upstate NY I literally trip over small closed bow runabouts laying in the weeds...so I dont want to throw money at this.

 

[raidercoop]

Re: Leaky aluminum boat - epoxy weld?

Well if you are looking for a low cost fix, then those epoxy rods are the way to go. They are running 6.99 per rod, and depending on how big the hole or void is will determine how many you would need. This buddy's boat had about three holes in the hull about the size of a pencil eraser and when we got done we still had over half of a rod left. Also after it sets you can sand and prime it for painting. Good luck

Raidercoop