Aluminum Jon Boat Repairs

[SonofaBoomer]

I have an old aluminum Jon Boat that has some leaks. I was wondering if anyone had some advice on making it water tight again. I am sure some of the rivets are old and leaking and need to be replaced.

What is the best practice to go about this? I probably need to use the solid aluminum rivets and coat them in marine sealant when I set them. It'll probably take a whole day to do the project since I have to remove the floorboards and outboard, I don't want to do it during the season because I use it weekly.

I have a good bilge pump on it and I just run it whenever the stern gets an inch or so of water in it. Not a huge deal, it's a redneck boat.

Tips on procedure and the right materials to use would be appreciated. Paints (fiberglass?), sealants, rivets, etc. Happy Independence Day!

 

[wings&wheels]

Look for cracks originating at sharp corners, rivet holes, backside of any brackets (where they flex the skin), etc. Use doublers on them as necessary.

If it were me, I'd drill out the rivets keeping a supply of the next size up handy, sealed/closed head, and use 3M 5200 to seal. Prep well to get a good sealing surface. Properly applied, 5200 is an incredible adhesive and sealant.

If it were me again, I'd look at my work and upgrade the bilge pump...just in case

Good luck! Old boats deserve to live on.

 

[55hambone]

I had a 10' jon boat years ago that leaked, but I had no idea where the leaks were. I put it on sawhorses and partially filled it with water and checked to see where it was dripping from. Several rivets were leaking. I had no means of replacing the rivets, so I used 1/4-20 bolts with nuts with nylon inserts and some 3M 5200 to seal them. I had it 3 more years and no leaks.

 

[Dodgetracker]

Alien seal spray.

 

[SC Maintenance]

I am curious. When I was a kid a neighbor fixed aluminum boats as a side gig. It was a 2 man operation to install new rivets. He had an electric hammer of some type. Is there a better way yet?

 

[SonofaBoomer]

I will have to put it on sawhorses and fill it up to find the leaks. It's nothing crazy maybe about an inch in the stern every 1-2 hrs depending on the load in the boat.

When we are sitting in the creek fishing with another adult or a couple kids it fills a bit faster.

The bilge is 1200 gph, it makes quick work of it lol. I am just thinking for the future. I know a guy that fiberglass epoxied his transom on his and he said you can do the whole boat. Don't know how that would hold up though.