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  1. JonM

    Repairing stress cracks in a riveted aluminum boat

    This is repair 2, I didn't have access to the inside. I had some help with lining up the holes in the patch but did pretty much everything else on my own. I put way too much 5200 on this one, I learned for the next ones. Some holes were slightly blown up in the boat but I was still able to pull...
  2. JonM

    Repairing stress cracks in a riveted aluminum boat

    This is repair 1 which was accessible from the inside. I did this repair with my boat tech and unfortunately we blew up the holes so I had to make washers from the scrap aluminum. I used the sheet-holders to pull everything together and riveted it. This patch seemed very sturdy, the rivets that...
  3. JonM

    Repairing stress cracks in a riveted aluminum boat

    I started repairing my boat last week and completed 2 of the 6 patches I need to make. It's not going so well, I have a few pictures I'd like to upload but the site isn't allowing me to upload them. It says "pic is too big" even after I compress the pics to under 1mb.
  4. JonM

    Repairing stress cracks in a riveted aluminum boat

    Thanks for your advice, I will try this when I start working on it tomorrow!
  5. JonM

    Repairing stress cracks in a riveted aluminum boat

    I'm getting those Cleco's by Monday night, a little sooner than expected. I'm bringing my boat to the marina that I repowered my boat with and my mechanic is helping me with the repairs. He's familiar with this repair job. We're going to lift the boat up on the travel lift and put it on stands...
  6. JonM

    Repairing stress cracks in a riveted aluminum boat

    Thanks I just ordered 3 of them, coming in on Tuesday next week. I'll keep you guys posted when I start the repairs.
  7. JonM

    Repairing stress cracks in a riveted aluminum boat

    How do these work? Can I use them if I only have access from the outside? I couldn't find any instructions online but I found them on that website from the part #. There's a floor in my boat so I don't have access from the inside.
  8. JonM

    Repairing stress cracks in a riveted aluminum boat

    This is the bad side where the hull is bending down towards the edge. The worst of it is from the rear to middle of the boat and it improves towards the front.
  9. JonM

    Repairing stress cracks in a riveted aluminum boat

    This is the good side but I noticed the hull is also starting to bend down a little bit towards the back of the boat. But this is the “good” side.
  10. JonM

    Repairing stress cracks in a riveted aluminum boat

    Sorry I was fishing on my friend's boat today. I will pull my boat out of the garage tomorrow morning and get you pictures of both sides. The hull has a good side (port side) which isn't bending and the bad side (starboard side) which is bending. I'll try to upload a video too
  11. JonM

    Repairing stress cracks in a riveted aluminum boat

    I don't know exactly how thick the hull is but it looks close to 1/8th of an inch thick. I bought 1/16th aluminum sheets from Amazon and two different sized 3/16th's rivets from "Jay-Cee Sales & Rivets, Inc". One pack of rivets with grip from .251-.375 and another pack with grip from .376-.500 ...
  12. JonM

    Repairing stress cracks in a riveted aluminum boat

    Is there a way to pull everything together from the outside of the hull before riveting on the patch? My concern is when I drill out these rivets holding the ribs to the hull, the ribs will separate and create a gap. Will the rivets pull everything together? There's also an indentation in the...
  13. JonM

    Repairing stress cracks in a riveted aluminum boat

    This was very helpful, thank you for the info and drawing
  14. JonM

    Repairing stress cracks in a riveted aluminum boat

    Repair 3, this one is also under the deck. Also all of these cracks are under the ribs. This boat is a 1997 Monark 16 SF (16' V bottom)
  15. JonM

    Repairing stress cracks in a riveted aluminum boat

    Repair 2, can't see this one from the inside because it's under the bench and floor/deck
  16. JonM

    Repairing stress cracks in a riveted aluminum boat

    This is repair 1 and it's the only repair that's accessible from the inside. What's concerning to me is how the hull is kind of peeling away from the edge of the rib inside the boat. Those lines that look like hairline cracks are just scratches. The cracks that go through to the inside are...
  17. JonM

    Repairing stress cracks in a riveted aluminum boat

    Thank you for your input, I will try my best to get more pictures today. It's going to be a couple weeks before I can attempt this repair because I'm recovering from a broken leg. But in the meantime I'm buying all the materials I need to successfully make this repair. Also I work at West Marine...
  18. JonM

    Repairing stress cracks in a riveted aluminum boat

    I have 5 stress cracks in my riveted aluminum boat on the starboard side and one stress crack on the port side. All the cracks are under the ribs closest to where the hull meets the sides of the boat. I've done some extensive research and it seems the best way to repair this is to drill a hole...
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