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Aluminum Hard Top repair - upper chesapeake

Old 10-19-2020, 12:20 PM
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Default Aluminum Hard Top repair - upper chesapeake

I searched a couple older threads for similar suggestions, hoping I can get some up-to-date recommendations.

I just bought a new-to-me '03 Hydra-Sports walkaround with a hard top. During the sea trial we noticed a crack almost all the way around one of the supports.



After a little negotiation decided to move ahead with the sale so now I'm looking for someone who can weld that shut, and possibly add a gusset plate to reinforce it a bit.

Boat is currently located in Elkton, MD. Bonus points if the person is mobile, boat has nearly a 9' beam so isn't technically supposed to be on the road without permits.

Old 10-19-2020, 05:37 PM
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Miller marine Fabrication in North East, MD.

He's a fantastic welder, not sure if he is mobile or not, but I wouldn't worry about pulling around a 9 ft beam.
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Old 10-19-2020, 06:30 PM
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Just bought a 2004 HS wa with the same problem. One side already had a patch weld and the other has a crack . Both same spot . I think I'm gonna get some brackets welded in between where it all meets right there.
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Old 10-19-2020, 07:40 PM
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Gussets. Then the crack will move up. Good luck.
Old 10-20-2020, 05:32 AM
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Originally Posted by BigtTunaDaddy View Post
Gussets. Then the crack will move up. Good luck.
Possibly. I’ve seen where folks have added additional bracing to limit side-to-side movement. We’ll cross that bridge when we get there.
Old 10-20-2020, 08:43 AM
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Originally Posted by CapPhil View Post
Miller marine Fabrication in North East, MD.

He's a fantastic welder, not sure if he is mobile or not, but I wouldn't worry about pulling around a 9 ft beam.
second for Miller Marine, did a great job on my t-top repair
Old 10-21-2020, 01:34 PM
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Hm. Did they go out of business or something? The only number I can find online (and their website) is disconnected.
Old 10-21-2020, 01:55 PM
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Originally Posted by TrybalRage View Post
Hm. Did they go out of business or something? The only number I can find online (and their website) is disconnected.
Is this the company you are trying to call?
Miller Marine Fabrication
410 287 0303
Old 10-21-2020, 03:44 PM
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Originally Posted by CapPhil View Post
Is this the company you are trying to call?
Miller Marine Fabrication
410 287 0303
Yes. Got a message that the number was changed, disconnected, not in service. Just called again and got the same message.
Old 10-21-2020, 06:05 PM
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Originally Posted by TrybalRage View Post
Yes. Got a message that the number was changed, disconnected, not in service. Just called again and got the same message.
interesting, I haven't talked to him in a few years. Isn't that old of a guy, wonder what the story is.

Could always drive down to his shop.
Old 10-22-2020, 08:56 AM
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bay boat works yard will know what's going on

410-287-8113
Old 10-23-2020, 04:28 PM
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A little out of your area, but try Carter Fabrications in Millersville, MD 410-987-9397. I recently used them to fix a small t-top crack and make a small section of aluminim tube with a 90 degree bend. They are nice people, the quality of work was good, and the price was fair.
Old 10-25-2020, 08:50 PM
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Bk fabrication in Preston just built a top for me. They did a great job. They actually answer the phone and do what they say they’re going to do which is rare now a days 🤦‍♂️ You can find them on Facebook or call them. 410-310-4292
Old 10-30-2020, 06:13 AM
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I had a similar problem with mine. I took mine to tex cool weld in Baltimore, it only cost $150 (they welded four cracks and put on two gussets). It could look better with some grinding and polishing but I told them I didn't care about looks. I didn't think it would hold up but I've pounded plenty of waves since then and its still holding up

Last edited by zam; 10-30-2020 at 06:19 AM.
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