How to Repair a Hole in an Aluminum Pontoon
Pontoon boats can be a lot of fun for family activities such as fishing or swimming, and are easy to drive and maintain. Pontoon boats are made for lower speed activities and cruising, and can easily navigate shallower waters than many other watercraft. Although the boats are strong and the pontoons are generally well constructed, damage can occur during hauling or launching activities. A cracked pontoon can collect water until the boat becomes unsafe and should be repaired immediately.
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Things You'll Need
- Drill and bits
- Wire brush
- Solvent
- Aluminum plate
- Marker
- Epoxy sealant
- Pop rivet gun
- Closed-end rivets
Instructions
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1
Clean the damaged area of the pontoon with a wire brush until the metal is free of corrosion or paint. Wash the metal with solvent to ensure the epoxy sealant makes a lasting bond.
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2
Cut a piece of aluminum to fit an area twice the size of the damage. Clean the patch with solvent and wipe dry to ensure a good bond. Bend or mold the patch to the contour of the pontoon. Drill four appropriate-sized holes for the rivets in the patch 1/2 inch from the edge at each corner.
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3
Place the patch over the damaged area of the pontoon and mark each drill hole on the pontoon. Ensure each mark is visible through the drilled holes in the patch. Remove the patch and drill the appropriate-sized holes for the pop rivets. Remove any burrs or loose metal from around the holes.
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4
Cover the damaged area of the pontoon and the face of the patch with the epoxy sealer. Coat the ends of the rivets with sealer as well. Place the patch over the damaged area and rivet it in place. Drill and rivet additional holes 1/2 inch from the edge around the perimeter of the patch to add strength and ensure a good seal. Wipe any excess epoxy from the outside of the patch.
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5
Let the epoxy and patch dry completely before launching and testing the repaired pontoon. Inspect the edges of the patch for a uniform seal and add additional epoxy as needed.
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Tips & Warnings
Be sure to choose the correct length rivet for the thickness of the aluminum pontoon and the patch.
Be sure the area to be repaired is clean before coating it with the sealant. Use a good quality epoxy such as Marine-Tex.
Choose pop rivets carefully: if they are too short, they may pull free. If they are too long, they will not pull the patch tight against the pontoon.
