For this video, a 3/8″ hole in an aluminum boat is repaired with Super Alloy 5 aluminum brazing kit and a Bernzomatic oxygen/MAPP gas torch with a size 3 or 4 tip. Propane or MAPP gas without an oxygen feed will not work on aluminum boats due to the aluminum heat dissipation.
Always clean the aluminum with an abrasive such as a sanding disk or wire wheel before starting your brazing process to ensure a proper bond.
Too much oxygen or gas will blow the torch out, so slowly adding oxygen to achieve optimum brazing flame is advised. Due to the small torch tip, you will need to add gas and oxygen until the flame appears as shown in the video.
To begin, broadly heat the parent metal with the torch to bring the parent metal to a working temperature of 600°F. Aluminum boats are large masses of metal which dissipate heat quickly, so preheating the aluminum boat is an important first step.
Once you’ve reached proper working temperature, quickly heat the aluminum rod, dip it into the powder flux, and apply the flux to the repair area. Watch as the flux transforms from powder to liquid, indicating that it’s time to apply the rod. Continue adding more flux and aluminum brazing rod until the hole is completely filled and sealed.
Troubleshooting tip: If the aluminum brazing rod balls up at any time, simply re-apply broad heat until you reach 600°F.
After completing the repair, allow the aluminum boat repair to cool and remove residual flux with water and a wire brush.
Super Alloy 5 is easier to apply and stronger than epoxy, and will not lift up or fall off over time—this aluminum boat repair is as strong as the parent metal and will last a lifetime. Super Alloy 5 can be used on sealing loose rivets, split seams, holes, cracks, dents, corrosion etc.
SUPER ALLOY 1 CANNOT BE USED TO REPAIR ALUMINUM BOATS. Please use Super Alloy 5 for aluminum boat repair.