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Hi, I bought a late 70s aluminum yacht last autumn and I'm in the process of making a few improvements to it. Running along the top edge of the hull (just below the toe rail) was a 6 inch strip of.� How should I repair and fill these holes? I'm guessing the first thing is to scrape out the paste with a wooden toothpick, sand the holes with some light grit aluminum oxide, passivate the area (I'll use Marine Grade Alumabrite), clean/degrease the area and then fill it with a Durafix (or similar) welding rod?� Boat: 50' aluminium power cat. Posts: Re: Advice: Random plugs/holes in top side of aluminum hull. What are they/how to rep. Would you have to ensure the alu rod/insert has the same nature as the original alu? ie. Only RUB /month. Aluminum Repair Process. STUDY. Flashcards. Although the use of aluminium for hulls has been limited, aluminium superstructures are becoming more common for both military and merchant ship construction. Vessels made solely from aluminium are primarily smaller-sized boats, such as fishing boats, pleasure boats, small passenger boats, gunboats and hydrofoils. The aluminium used for shipbuilding and repair is generally alloyed with manganese, magnesium, silicon and/or zinc. These alloys offer good strength, corrosion resistance and weldability.� The ship repair process is much like the new construction process, except that it is generally on a smaller scale and is performed at a faster pace. The repair process requires a more timely coordination and an aggressive bidding process for ship repair contracts.

Early in my career I worked for a dealership that sold production boats, every Aluminium Hull Repair Center one of which was equipped with painted aluminum arches. Invariably, the paint would blister, in some cases before the vessels were offloaded from delivery trailers, and warranty claims were dutifully submitted, which the builder, to its credit, promptly paid.

In an effort to stem the cash flow, the company earnestly focused on improving the preparation and paint application processes. Yet the problem persisted. A few years later, I was managing a boatyard where painting aluminum spars was common. Leery of experiencing the same sort of failure, I began reviewing old spars and other painted aluminum hardware.

I noticed that nearly all the failures occurred adjacent to a hardware installation, a fastener, a spreader, a step, or some other fitting�an area where the paint coating had necessarily been upset or breached. I believed I was onto something. Here, the screws damaged the paint when they were installed, allowing water to migrate under the coating. Among other attributes, marine-grade aluminum alloys, those in the and series, are naturally corrosion resistant. When exposed to air, oxygenated seawater, or fresh water, aluminum quickly develops a tough, transparent oxide film Aluminium Hull Repair 8.5 that is resistant to corrosion.

There is, however, an aesthetic price for this durability. Left to the elements, aluminum develops a dull gray�and eventually dusty, gritty�finish; for military, pilot, fishing, and utilitarian applications, that finish can be a thing of beauty, as it lowers building and maintenance costs. The white powdery material, aluminum oxide, forms when aluminum is robbed of oxygen in a wet environment.

Enter two-part paints. However, once painted, aluminum can no longer develop its tough, clear, corrosion-resistant oxide coating. The paint works well until it is breached, and water enters the rift. This breach could be caused by a fastener, an antenna base, a navigation light, a hinge, a lockset, a nick, or a scratch�and it could be microscopic. Initially the wound is self-healing: The oxide coating forms, but instead of protecting the aluminum, it lifts the edge of the paint and allows water to migrate farther under the coating.

At that point, the chemical equation changes, as moisture and aluminum, in the absence of air, are the ideal incubators for a phenomenon known as poultice corrosion. When this happens, the aluminum pits and produces copious amounts of aluminum oxide powder or, when wet, aluminum hydroxide, which looks a bit like freezer-burned vanilla ice cream. The formation of the oxide or hydroxide lifts the paint, causing the familiar and unsightly blister, which eventually falls off, exposing raw, pitted aluminum.

Corrosion is also a problem on sharp, or unradiused, edges. In these areas, paint applied to the sharp edge tends to run off, making it too thin to be protective. Those areas also tend to suffer from abrasion abuse. Others who have come to similar conclusions have tried to prevent corrosion by inserting plastic or another nonmetallic bushing or insulator between the hardware and the painted aluminum structure. And, when water makes its way between the insulator and the painted surface, as it always does, poultice corrosion will begin.

The best solution is prevention; when installing hardware on painted aluminum surfaces, liberally bed with polyurethane or polysulfide sealant. Therefore, instead of attempting to prevent the damage, an effort I believe is futile, assume it will occur and mitigate its effects. The sealant prevents water intrusion, rendering the paint wound inert.

Fastener threads should be similarly treated. If insulators are used, the surface between the insulator and the paint should be bedded. Sharp edges should be gently rounded before being painted. That alone will prevent the thin-paint phenomenon, coating failure, and subsequent corrosion.

All paint applications benefit from proper surface preparation, priming, and best industry paint application practices, and aluminum is no exception. Using these, as well as the liberal hardware bedding technique and quickly repairing damage, paint applied over aluminum can last for a decade or more. Acknowledging the difficulty of old-fiberglass-boat disposal is essential to developing a complete life-cycle plan for the industry. Ideas from a number of countries suggest practical next steps in making sure� Read more �.

If this Finnish builder of luxury yachts is any indication, composites made with natural fibers are inching closer to mainstream boatbuilding applications. Later this year, Baltic Yachts, operating miles� Read more �. Read more Construction , Materials , Repair articles.

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