How to Repair an Aluminum Boat Deck

The deck on an aluminum boat is frequently subjected to stresses that lead to cracks in its welds. In days past, these cracked welds would have required the assistance of a welder before the boat was launched again. But new sealants mean a cracked weld or a pinhole can be repaired by the boat owner without resorting to a full-blown welding job. The process is straightforward and ensures the deck is watertight.

Things You'll Need

  • Gluvit Epoxy Sealer kit
  • Acetone or aluminum prep wash
  • 80- to 100-grit sandpaper
  • Old paintbrush
  • Marine paint
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Instructions

  1. Cracked Welds

    • 1

      Scrub the area requiring repair with an acetone-soaked, clean cloth. Rinse the area with running water and a hose, and allow it to air-dry thoroughly. Using a specialized aluminum prep wash is an option, but acetone is a suitable substitute.

    • 2

      Mix two-part epoxy putty using 5 parts putty to 1 part hardener by volume. Fill any divots in the deck more than 1/8-inch deep with the putty. Sand the area requiring repair with 80- to 100-grit sandpaper and a palm sander. Allow the putty to set completely.

    • 3

      Mix epoxy sealer resin with the hardener -- also 5 to 1 -- that accompanies the resin in a clean container. Apply the sealer to the damaged area using a disposable paintbrush.

    • 4

      Place signage, or rope the repaired area off. Allow the sealer to cure for 12 hours at 72 degrees, then apply a second coat as per the directions in Step 3. Allow the sealant to cure for 48 hours.

    • 5

      Optional: Remove the gloss finish from the sealer using 80- to 100-grit sandpaper, then coat the repair with marine-specific paint.