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DIY Boat Projects: Cleaning Aluminum - Florida Sportsman

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Only a large router at CJM was able to tackle this. Waterjet: a good option and many shops have a machine large enough to cut your parts. The downside is edge prep. The waterjet leaves sand particles in the surface of the weld. You will need to grind all the edges before welding. Router: the best option for boat building due to large tables and no edge prep. The downside is that detailed cutting is limited to the size of the end mill being used.

As most boat designs have been designed for a CNC router, this is not normally an issue unless there is an operator error. While a router is a great option, a bit of cleanup might be required. I found some interference issues in the joints of my jig, which required me to get in there with a little file and take out the cutter radius to make the jig fit correctly.

This is bad. Got it!? Ok good. Well, if you can afford a pulse mig machine, this is what you want. Professional boat builders will only use this kind of machine. However, they cost your first born child to buy, so maybe see if you can rent one for your build. If a pulse mig is not an option, you need a spool gun for your welding machine. They are reasonably priced and most major manufacturers make them.

You will need exceptional welding skills to use a standard spool gun though. Practice your different welds. Avoid burning through. I have been welding for 17 years and completely burned through my first boat.

Even better, hire a friend with boat-building skills. Have them go over the welding techniques with you. You will thank us later for this. The design files come with a jig. I chose to put mine on some custom-built sawhorses. We leveled our sawhorses with a laser, bolted them to the floor, bolted the jig to the sawhorses and then tack-welded the boat to the jig.

Some builders choose not to tack weld the jig. The primary idea behind back step welding is to eliminate distortion as much as possible. This is very important.

Weld towards the middle of the boat, but sequencing your welds out for the middle. I had to shorten the EPS foam a little because of the new seat supports, but the high density stuff fit right underneath where it used to be.

The holes I'd drilled lined right up and the seats went in with their new hardware without any issues. Each seat also had a pair of brackets to reinforce the rim of the hull and keep the boat from twisting under load. First I soaked them in some rust remover for a couple of days, but that had no effect. I ended up putting them in a vice and using a sawzall to cut off the screw parts flush with the back of the brackets.

Then with a drill press and progressively larger bits, I took out the screw heads from the inside until I could crack off what was left with a large phillips screwdriver. Fortunately, this worked well and I didn't damage any of the brackets. Back to the Flex Seal. Everywhere a piece of stainless went through wood or through the hull, I wanted to seal it to prevent another round of rust and corrosion welding.

You don't want to overdo it on the darker ones especially in a marsh but you do need some. Reply 3 years ago.

Thanks jase! They're around, keep your eye on Craigslist. Even if you spend the other half on paint, plywood, and rivets, you still end up with something better than you could ever buy new.

Introduction: Aluminum Boat Restoration. By BennyOne Follow. More by the author:. About: I'm a professional recycler in Oakland, CA. I make most of my own furniture and like to build everything from houses to chicken coops.

I make surfboards, � More About BennyOne �. This project started when my dad said, "The motor seems a little wobbly. Can you take a look? I'll drag it home where I've got my tools. I had to fix the breach with some JB Weld. Love that stuff. I painted the shiny spots with metal primer.

Thanks for reading and I hope you liked my Instructable! Its entered in the Outside contest, so if you think its worthy, please give me a vote.

Participated in the Outside Contest View Contest. Did you make this project? Share it with us! Without question, these are the most versatile boats we build. The Bullnose is hard at work every day, utilized by contractors, divers, transporters, emergency responders, islanders, and many more. Stanley Passenger boats are designed with the comfort and safety of both passengers and crew in mind.

Our sales and engineering teams work with clients to design a boat that meets their specific passenger carrying demands. Learn More. Stanley custom-built barges are used by agencies and industries in a huge range of applications: vehicle ferrying, marine cable service, heavy equipment and materials transport, to name a few. Carry everything you need safely. Fire Rescue Stanley fire rescue boats are deployed worldwide, providing emergency Aluminum Boats California Kitchen responders with the tools they need to save lives and property in the most challenging conditions.

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