How to Weld on an Aluminum Boat

An aluminum boat, like any other boat, can become damaged while in the water, or even while it is docked. The best way to repair this damage is through welding the area. This is not a difficult process, although some additional steps need to be taken if the aluminum is particularly thick.

What you will need:

Wire brush, welding safety equipment (hood and gloves), welder with spool gun

Directions:

1. Before starting on the welding, make sure the aluminum is completely cleaned off. Go over the area you are planning to weld with a wire brush. Make sure that this is done over the area to be weld, as well as surrounding it. You need to make sure that oxide buildup is removed so the welding can be done properly.


2. If the area is thick, go ahead and preheat it so the weld will take better, and will result in a more structurally sound, longer lasting weld. In areas that are not thick (typically less than 3/16 of an inch in thickness), then a preheat of the aluminum is not required.


3. Weld in a zigzag pattern, moving along the surface of the welding area carefully and slowly to make sure it penetrates properly, and that the weld gets to all the areas in an even manner. Use the thickness of the aluminum as a guide to how quickly you will be welding the area.


4. Let the aluminum cool prior to making any additional changes. You can ground down the welded area if in a spot you don't want to be seen, and can finish it with paint or polish.