How to Repair an Aluminum Pontoon

Pontoon boats are relatively inexpensive and easy to maintain. They achieve buoyancy by means of two (or more) aluminum pontoons that hold the boat desk above the water. They're perfect for fishing or just hanging out on the lake with friends. Unfortunately, due to their lightweight nature, aluminum pontoons can become damaged easily. Repairing an aluminum pontoon isn't a difficult task, as long as you take the time to perform the repair carefully.

Things You'll Need

• Damaged aluminum pontoon
• Wire brush
• Rag
• Solvent
• Epoxy and sealer
• Aluminum patch
• Aluminum cutting tools
• Drill
• Pop rivets
• Rivet hammer

Instructions

1. Raise the aluminum pontoon out of the water. It needs to be kept clean and dry to repair the damaged portion.

2. Scrape around the hole and damaged area with a stiff wire brush. This will ensure that the aluminum is clean of debris and allow the patch to adhere better.

3. Pour solvent onto a rag and use this to wash off the area you will be repairing. This will ensure that the epoxy sealant will have a strong bond.

4. Measure the repair area. You want your aluminum patch to be at least twice the size of this. Cut the aluminum patch. Place it over the area to be repaired to check for proper fit. Fold or bend the patch to match the shape of the pontoon.

5. Drill a rivet hole in each corner of the patch according to the size of your rivets. Be careful not to damage the patch's shape so that it will still fit on the pontoon properly.

6. Brush the inside of the patch with the epoxy solution.

7. Hold the patch in place over the pontoon and mark through the drill holes you made in Step 5 on the pontoon.

8. Set the patch aside. Drill holes in the pontoon through the marks you made in Step 7. Use a file and sandpaper to make sure the holes are clean and clear of any burrs.

9. Brush the pontoon repair area, the inside of the patch and the ends of the rivets with the epoxy sealant. Allow this to dry according to manufacturer's instructions seal. Wipe any excess epoxy from the outside of the patch.

10. Hold the patch over the repair area and rivets the four corners into place.

11. Drill a few more rivet holes at least 1/2 inch away from the edge of the patch. Insert rivets. This will help to seal the patch in place and give it added strength.

12. Allow the epoxy to dry according to the manufacturer's instructions.

13. Test the aluminum pontoon and patch for leaks. Add additional epoxy as needed.

Tips & Warnings

• Make sure to get the right length of rivet for your particular pontoon thickness. A rivet that is too long or too short will not hold the patch in place properly.

• Always use the proper safety equipment when working with power tools.

• Use a mask and goggles when using strong chemicals such as epoxies.

References

• theboatshopmotorparts.com: Pontoon Leak Repair

Resources

• Read this Article in Spanish
• Pontoonstuff.com: Pontoon Information and Repair Kits