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Message: <blockquote data-quote="thill" data-source="post: 508491" data-attributes="member: 4972">I recently had a boat transom that looked much like that:[ATTACH=full]118353[/ATTACH]As you can see, it had a bunch of holes all over it.  More than you can see in the pic.   I used a MIG welder, a roll of aluminum wire and a bottle of argon gas to do concentric "doughnuts" around each hole to close them up.   Most of the holes expanded greatly when the arc first hit them, due to corrosion underneath.     That's a good thing, believe it or not.   You have to get all that stuff out.  Many little screw holes expanded to the size of a nickel.     But a wire feed welder makes it easy.   I did each one carefully, sanded, and re welded ones that seemed thin or had pinholes.    In the end, it turned out amazingly perfect.  Here is the Swiss-cheese transom after repair, flap disc sanding and aluminum primer:[ATTACH=full]118354[/ATTACH]Here it is after the first coat of industrial enamel:[ATTACH=full]118355[/ATTACH]Here is a shot after the motor went back on:[ATTACH=full]118356[/ATTACH]And finally, here is the boat in use.  Does not leak even a drop of water all day long.   I'm very happy with my amateur attempts at welding aluminum:[ATTACH=full]118357[/ATTACH][ATTACH=full]118358[/ATTACH]The pic you showed looked terrible, with the paint around the border, making it look like a piece of scrap metal, but it may not be as bad as that pic made it look.   I think I could fix it properly, but worst case, you could take it to a welding shop and get the holes closed up.</blockquote>

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