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After grinding the welds I took a flap wheel over everything lightly. It feels pretty solid now, my ugly welds are working…lol I am learning how to weld aluminum, one way or another.

I ran four practice beads on some .125” coupons, and then cleaned the cracked areas, prior to welding on my side console. I welded a couple short cracks first and then welded the gaps closed. I took a picture of the short welds. My big gap filling welds looked like the last ones I pictured. I...

I welded the other side of the same part yesterday. I was using my O/A torch to heat & wire brush the surface, cleaning it. I got it a little too hot in one area and the aluminum sheet started to melt and fall away. I eventually welded it solid, but it’s ugly. Still learning obviously.

yeah, it suck when you sharpen a new tungsten and then proceed to dip it … gotta start over. The area I welded didn't have that big gap, that’s why I stopped at the gap. Baby steps

33 CFR § 183.53 - Horsepower capacity According to the rule above. In the absence of a manufacturer plate stating max HP, there is a formula to guide you concerning horsepower capacity on a small boat. For example a 16’ boat with a 72” beam at the transom, with a 20” transom, and a steering...

I ran a couple of practice beads on some aluminum .125” sheet coupons. I figured what the hell, and stated welding on the side console that is full of cracks. The repaired area pictured has a total of four beads, that I ran across the area. I know it’s not a pretty, professional looking weld...

I would leave it. Lightly scuff & clean it, and then prime/paint over it.

That gold colored bare skin looks like alodine, which is a surface treatment to aid paint adhesionn while inhibiting corrosion. It is commonly used when painting aluminum aircraft. Nice boat!

I covered the 2 x 4 bunks with some leftover indoor/outdoor carpet I had left over from another project. I used a can of gorilla spray contact cement, and some galvanized staples to secure the carpet to the wood bunks. The bunks are installed on the trailer. I still need to run the wiring for...

Thanks for the tips. I’ll give it a try. This machine is pretty basic, but it should be OK for welding the relatively thin aluminum I am working with. I’m surprised you like the choice, I was ready to hear the opposite concerning my choice of welding machine.

When an aluminum boat is manufactured, solid rivets are used because they are superior in strength & longevity. If you drill out solid rivets during your overhaul, and then reassemble using blind rivets, AKA pop rivets, you are sacrificing strength for convenience, because it’s easy to slap in...

When you said Solid Rivet, I believe you meant to say Closed Rivet. A solid rivet must be “Bucked”, which is a process of mechanically deforming or expanding the end of the rivet. When you drive a solid rivet, a pneumatic rivet gun is used, along with a heavy chunk of steel called a bucking...

I should be finished with the MIG welder for now. Hopefully I’ll start the aluminum welding this weekend, with my TIG welder. I’ll post a picture of my settings and some practice welds.

Everywhere I welded I had to grind off the galvanized coating on this trailer. When I was done welding, I cleaned up the bare spots with a wire brush and or flap wheel. I applied rust converter before applying rust oleum galvanized spray paint. I’m not sure how it’s going to hold up??? I guess...

Last weekend I had to drive out to Boone NC, to fetch my kid. He spent a few days at home since it’s between semesters, so I didn’t work on the boat much. This week it rained or was forecast to rain every afternoon, so it’s been slow going. I drove my truck over the bent pipe to straighten it...

With the tongue welded in place, and the tongue jack installed, it sits slightly nose high with the Jack fully extended and no weight on the trailer. I am happy with how this part worked out. The leaf springs seem a little stiff, even with the boat on it. I wonder if I should remove a leaf or...

I made some good progress today, I guess the cooler weather (hi 80’s vice mid 90’s) helps. I ended up driving my Duramax onto the 12’ 8” tongue beam (3”x 3” .125 wall thickness). I set the beam on wood blocks, placed strategically so the weight of the truck bent the beam. I got it pretty...

I welded four plates to the frame where the original crossmember was, and where the crooked rusty cross member was. I tacked a steel 2”x 2” angle in place. I cut the 1 7/8” hitch off the end of the tongue tube, and the T off the opposing end. The tongue tube is now a bare tube and it has a...

It is definitely bent, twisted, and knocked out of whack. It is not your eyes…lol As far as being out of alignment, I doubt it was much better when it was new based on the modular design of this trailer. The axle & fender assembly is held in place on the main frame using four clamps. It...

Take the hood off the motor. You should be able to turn the flywheel by hand if it isn’t seized.