Aluminum Jon Boat Hole Repair with a Bernzomatic Torch and Super Alloy 5 Aluminum Repair Kit

A 3/8" hole in an aluminum boat is repaired with Super Alloy 5 1/16'" aluminum welding rod and a Bernzomatic torch (https://www.muggyweld.com/product/bernzomatic-bz8250ht-torch/) with an oxygen/MAPP gas tank. Always clean the aluminum with an abrasive such as a sanding disk, stainless wire wheel, etc., before brazing with Super Alloy 5 to remove oxidation and impurities from the parent metal.

This technique and product can repair holes, tears, seams, etc., on all types of aluminum Jon boats. After a good visual cleaning with the mechanical disks and brushes, Super Alloy flux will help clean out the impurities embedded in the aluminum. The Super Alloy 5 flux is used to support the rod flow and bond to the parent aluminum and seal cracks/holes. Use the same process when sealing rivets and seams.

Keep the flux container as close to the project as possible to prevent the aluminum from cooling too much while going for additional flux. Always keep the torch moving when working on thinner aluminum, as the aluminum doesn't give an indicator as to when it will fall away.

If you already have the 3/32" rod and need a thinner rod, you can hammer the alloy flat to the desired thickness.

Aluminum boats over 14 feet will need oxyacetylene and a size 2 or larger tip due to the thicker aluminum.

Note: Propane or MAPP gas without an oxygen feed will not work on aluminum boats due to the rapid aluminum heat dissipation--the parent metal must reach and stay at 600℉ to allow the rod and flux to flow and seal as shown.

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Please read all instructions prior to use at: https://www.muggyweld.com/wp-content/uploads/2017/04/Super-Alloy-5-instructions.pdf

For more videos and information, or to order, visit https://www.muggyweld.com/product/super-alloy-5/

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