Fixing Holes in an Aluminum Boat. This video shows a technique of repairing holes in an aluminum boat which works for holes up to 1/4" in diameter. Full instructions below. Please, feel free to ask questions.
1- The closed end rivets used to plug the holes are usually available in 1/8", 3/16" or 1/4" diameter. Measure the diameter of the holes you need to plug and choose the smallest rivet that is larger than the hole. So if you measured .180" you would choose 3/16" rivets and if you measured .190" you would choose 1/4" rivets.
2- Using a drill bit that matches the diameter of the rivets you have selected, drill out the holes you will be repairing.
3- Apply a bead of 5200 sealant to the end of the rivet and insert it into the hole from the outside of the boat.
4- On the inside of the boat, slide a rivet washer over the end of the rivet.
5- Set the rivet.
6- Optionally, clean up the extra 5200 sealant around the rivet head with a rag or paper towel before it cures. You do not need to worry about wiping too much away. The only sealant that you actually need is locked between the head of the rivet and the rivet washer.
-closed end aluminum blind rivets (aluminum body / aluminum shank)
-drill bit matching rivet diameter
-aluminum rivet washers matching rivet diameter
-rivet setting tool with die installed to match rivets you are using
-3M 5200 marine adhesive sealant (regular or fast cure)
Where to buy materials:
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