Aluminum Boat Welding DIY Tips: How to Repair a Seam

What’s the Best Way to Fix an Aluminum Boat?

Aluminum boats have become increasingly popular in recent years. Aluminum boat welding technology allows for a durable, sturdy boat that won’t crack easily the way fiberglass does. Plus, aluminum is an affordable and lightweight material that is ideal for many types of boats, including, pontoons, rafts, canoes, airboats, and more.

That being said, there are a few challenges that come along with having an aluminum boat. Maintenance on an aluminum boat is different than maintenance on a fiberglass boat. The material can corrode if it’s not maintained. It’s important to understand how to maintain and fix an aluminum boat if you own one or if you’re thinking about getting one.

In this video, an aluminum boat with a separated seam is repaired quickly and easily, using Super Alloy 5 and an oxyacetylene torch.

Oxyacetylene, oxy-MAPP gas, or oxy-propane is required for all aluminum boat repairs, as aluminum dissipates heat quickly.  Super Alloy 5’s powder flux liquefies at 600 degrees, indicating that the parent metal has reached the proper working temperature to deposit the rod.  In addition to acting as an absolute temperature guide, the flux also removes surface contaminates, allowing the user to make repairs without pre-cleaning the parent metal–a technique superior to MIG and TIG applications.

The procedure featured in this video can be used for many aluminum boat repairs:  cracks, splits, holes, rivets, and areas worn thin by rocks and gravel–and can be used on all types of boats:   aluminum pontoon boats, airboats,  canoes, rafts, props and cast aluminum outboard motors.

How NOT To Fix an Aluminum Boat

If you’re like most people, you’d much rather be out on the water than fixing your boat! With the wrong repair method, you’ll be fixing it over and over again – not to mention, bailing out water every time your boat springs a leak. With the right method, your boat will be as good as new after just one repair!

When faced with a damaged seam, many boat owners turn to epoxy. Epoxy is a rubbery substance that works for minor, temporary repairs. However, when it comes to aluminum boats, it definitely isn’t a long-term solution. It is unreliable, so you never know when it will fail – you’ll just have to hope that it won’t fail while you’re out on the water. In any case, you’ll have to repeat the process when the epoxy eventually peels off.

Aluminum Boat Welding: The Best Method for Permanent Repairs

The best way to fix a hole or a split seam is to use a metal-to-metal bond. If you’re not a professional welder, no worries – aluminum boat welding is something you can do yourself with a product like Super Alloy 5!

Super Alloy 5 is a permanent solution with a bonding strength of 30,000 psi. You don’t need expensive welding equipment or extensive knowledge. It’s easy to do and it’s portable. You can keep a torch and Super Alloy 5 in your truck so that you always have a solution in case of emergencies.

How to Use Super Alloy 5

You’ll need an oxyacetylene torch, Super Alloy 5 powder flux, and an aluminum brazing rod.

Always heat the surrounding area so that the cold metal around the seam won’t leach all the heat from your work area. Once the area is thoroughly heated, use your torch to heat the tip of the rod, dip it into the jar of flux, and melt the flux off the rod onto the weld area. Start depositing rod and add more flux as needed. The Super Alloy 5 flux will assist with the bonding process as you apply rod.

Find full instructions and tips HERE.

Make Aluminum Boat Welding EASY!

No more dealing with separated seams – in just minutes, you can get a watertight, permanent joint that won’t pop apart or peel up. Try Super Alloy 5 from Muggy Weld for all your aluminum boat repair needs!


NotePlease observe all AWS Safety & Health Guidelines when using Muggy Weld products.