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Random Quote: It'll make sense when it happens. . .
what kind of repair? is it a structural issue or a hole in the hull? tig welding is the preferred method but there are aluminium epoxies out there that would work for a hole in the hull but I wouldn't trust them for a structural repair.
You can tell if the boat is welded or riveted by looking at the seams where the pieces of aluminum are joined together. On welded boats, it will look like a continuous line of toothpaste was squeezed out on the seam, while on a riveted boat, you will see a line of separate raised bumps on the seam.
They also need to know (a) how big the problem you want patched is (b) is it a hole or a crack (c) is the problem in the hull (the main tub that makes up the outside of the boat), or just in a seat or something.
__________________ When blithe to argument I come, Though armed with facts and merry; May Providence protect me from, The Fool as adversary. Whose mind to him a kingdom is, Where reason lacks dominion; Who calls conviction prejudice, and prejudice opinion.... ;-)
If its just small pin holes,best way would to have it tig welded.The only problem with that is the alum can break down if not done right.It can crack if it gets to hot.
there are pits and some holes
the thickness 1/8 to 3/8
no the hole are not in the welds
yes in the transom & some on the bottom
I would like to find a good product to coat the transom with
My first three boats and 10 years of my boating life were made from aluminum, 14', 18' & 22'. I used JB Weld to patch the small holes and small cracks (HomeDepot carries it). Once the leaks were getting a little too much I'd fill the boat with water past the waterline while it was in its trailer. I'd mark the leaks underneath. Then clean the area around the holes, rough up with a file or coarse sandpaper, wipe with iso alcohol before applying JB Weld. Very easy and always sealed for as long as I had each boat.
Holes from electrolysis? I'd be worried that the aluminum has been eaten away over wider areas than just the holes. Even if you do patch the holes, you may have very thin aluminum on the rest of the sub-waterline portion of the hull. Might bear a bit of investigation before putting a lot of time, money and effort into your repair.
Location: Quebec, Canada and Pirates Cove, OBX, NC
Posts: 17,813
Re: Aluminum boat repair
Your problem seems to be pitts and not structural damage . . . no damage in the welds
The top of the line product is Belzona . . . I used it on my boat for electrolisis repairs . . . good stuff . . . it is what the Coasties use . . . very expensive
You will need three very thin applications to fill pitts . . . this stuff is very hard to sand once it hardens . . . never apply a thick layer with the intention to sand down later, you will hate yourself for that decision
Do not apply like body filler . . . way to expensive and you will spend the next six months sanding
Aluminum boat repair 
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