What to use on failed weld on an aluminum hull crack

[sfmeyer]

What to use on a failed weld on an aluminum hull crack?

This is a 1982 Bass Tracker by Sea Nymph. Two 12" welds on the same seam lasted for 4 years, but after a second attempt to fix another leak in between, the aluminum is just too far gone to do it right. My friend and welder was chasing holes so we closed them up as best as possible, but she is still leaking a bit.

I understand the first reaction of most on this forum is A) glad it's not me and B) trash the hull!! Haha

However, if I really wanted to make the most out of its remaining life, say 5-10 years, how would you go about a chance at the repair?

My thoughts/options were:

1) JB Weld around the ugly existing weld for smoothness and security but I worry it would make it worse.

2) gluvit the entire exterior, followed by a primer and paint for UV protection, etc.

3) 3M 5200 the inside of the weld after the exterior work had fully cured.

I won't put much money into it and I understand this thing is near the end of its life, but I would really enjoy a few more years out of it. Thank you greatly for any advice, shared experiences, and suggestions.

Having trouble getting my pictures small enough, coming soon..

 

[sfmeyer]

No Title

Another angle, the weld is rough.

 

[sfmeyer]

I even wonder if this could be a time to try those low heat brazing rods? There is plenty of metal there, just need to fill it in some. Any (inevitable) future repairs would be a lot easier to make if it wasn't filled with gunk.

 

[ondarvr]

Have it cleaned up and welded by someone that knows what they're doing, and maybe they'll need to add some additional support for that area.

​The rest of the methods you listed will work right up until you put it in the water

 

[jbcurt00]

On a rivetted boat, I'd recommend a rivetted repair/patch.

Seen a few welded repairs fail and/or leak, but cant remember a single rivetted repair failure....

 

[sfmeyer]

No Title

I had a 2 welding companies say they wouldn't touch it based on the age and wear of the aluminum, I really don't think it is my weldor but I understand that valid response.

I'm also not sure a rivetted patch is possible on the contour of the hull where it is? Thanks for the suggestion.

 

[ondarvr]

This is why after a certain period of time aluminum boats tend to get scrapped, the fatigue in high stress areas weakens it to the point of making it very difficult to repair. At this point, as a last resort repair, you could drill the ends of the cracks, slather it with 5200, then rivet a piece aluminum over the area. It'll be waterproof for a while at least.

 

[jbcurt00]

Guys have made patches to repair chines, so a panel could be bent to fit, possibly have to remove a few factory rivets too.

But it could be done.

 

[kcassells]

Go to a metal shop with a "Mold" and have them fabricate a new pc. that covers over that/and extends 3' each way. They can bend it, then redrill and pop rivet etc.Might want to look at all other possible weak areas and do it 1x. JMHO.

 

[sfmeyer]

Go to a metal shop with a "Mold" and have them fabricate a new pc. that covers over that/and extends 3' each way. They can bend it, then redrill and pop rivet etc.Might want to look at all other possible weak areas and do it 1x. JMHO.

I just had a friend come over to talk some sense into me. I'm going to do a legitimate repair similar to this.

Thank you guys for the posts, I will update the thread.

 

[Scott Danforth]

A good welder/fabricator can repair that without a problem. Some 0.090 thick 5052 aluminum sheet and an hour worth of work and you would bever know it was repaired

 

[sfmeyer]

Could someone please elaborate on the RIGHT way to do this repair? The only welder/fabricator I can find wants $500 and no guarantee.

If I put a patch piece of 0.09" 5052, properly and fitted nicely over the beam, should I -

1. Rivet it in place and weld it on over the top?

2. No rivet needed, just weld it on over the top?

3. Cut out the aluminum on the boat where the patch piece will go and weld it in flush?

Does anyone have picture of a proper repair that is similar? I really want to do this right, and I'm finding it tough to research online and wade through all the jb welds, sealants, epoxies, brazing rod fixes, etc. I sincerely appreciate the help here. Thank you.

 

[sfmeyer]

No Title

Here is where I'm at. My welder wants to give it another shot if I can come up with the best plan of attack. Out here in Arizona, I'm having trouble finding the reputable repair guy that seems to exist in a lot of other places. Thanks guys.

 

[bruceb58]

Is your welder using TIG or MIG. If he isn't using TIG, find another welder. That first weld looks like it was done with a MIG welder and it looks horrible. Bunch of metal blobs without any penetration into the base metal.

 

[sfmeyer]

I started by grinding down the blob of weld and getting two 48" patches of 5052 cut and bent to the angle of the hull runners. It took some time but I finally found a well-reviewed welder that was willing to do the job. It definitely was not an easy task he had, but he turned a real mess into a thing of beauty. THANK YOU to everyone who chimed in.

 

[Big Gee]

That came out nice. :thumb:

 

[eggs712]

Those are good looking beads from what I can see. (The new ones, lol)