How To Fix A Hole In An Aluminum Boat – Simple Guide to Patching Holes

Hole in a boat? That can only mean one thing – Head over to the recycling bin.

Or, does it?

We live in wonderful times! There’s an answer for almost every problem here today including this massive one. That is why gone are the days when a hole in your aluminum boat meant the end of the world!

How To Fix A Hole In An Aluminum Boat

How To Fix A Hole In An Aluminum BoatAll you need is some epoxy, sandpaper, silica, glass fabric, and some time. Your aluminum boat will be fully functional and aesthetic soon. We have listed out all the steps in as much detail as possible for you.

  • Start by cleaning the metal and shaping it into its original shape. You will need a hammer for the shaping process. Depending on how the hole is, you can shape the torn edges and cut the sharp ends away so that the aluminum is flat and ready to be repaired. 
  • Now, you should use a 120 grit sandpaper to soften the aluminum edges. With a bristle disc you can remove the paint around the hole and then soften it again with an 80 grit sandpaper.
  • Use glass fabric to make the patches. You will need 1 for the outside and 3 of different sizes for the inside (big, small, smaller).
  • Apply epoxy on both sides and ensure that it reaches the dings and the scratches equally. If there are small holes that are hard to reach, you can fill them up with colloidal silica.
  • It is now time to apply the patch. Apply one outside and let it sit on the thickened mixture. Stack the three you cut for the inner side and make sure there are no air bubbles. Use a squeegee if needed.
  • Leave this overnight for curing.
  • After 12-24 hours, start grounding the edges so there are no rough areas or edges and use a low density filler to fair all the patches.
  • Allow this to cure as well.
  • Now, you just need to apply pigment so that the patch blends with the rest of your boat.
  • After another round of curing, you can use your boat as usual. But, don’t forget to test it first!

People also ask

1) Is JB Weld good for aluminum boats?

Yes, it is excellent for aluminum boats as well as other metals, fiberglass, and composites.

2) What is the best epoxy for aluminum?

JB Weld, Hy-Poxy, and Permatex are good choices.

3) What is the strongest adhesive for aluminum?

Our vote goes to Loctite Weld.

4) What kind of glue can you use on aluminum?

Any glue that has cyanoacrylate is a good choice.

5) Can you put epoxy on aluminum?

Yes, you can.


Fixing a hole in an aluminum boat is easier than you think. There are many good products on the market that can help you do this yourself without relying on a professional. We hope our guide helped you with the same. If you have any more questions, please reach out to us.

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