Finally got tired of the intermittent use of the bilge in my jon boat while on fishing trips.
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Photo 2—Left, a coarse 3M® Roloc™ Bristle Disc did a good job of removing paint around the repair after it was hammered back into shape. For the patch, we cut a single piece of 745 (12 oz) Episize™ Glass Fabric for the outside and three pieces (in diminishing sizes) for the inside. We started with the single layer outside patch, applying it to the hull centered over the hole and smoothing it into the thickened mixture (Photo 6). Photo 6—A single layer of glass was applied to the outside of the hull and smoothed into the thickened epoxy.
Photo 7—Three layers of glass were laid in position on the inside of the hull and lightly squeegeed to remove trapped air.
Aluminum EpoxyALUMINUM EPOXYTemperature, aluminum-filled, two-component resin hardener epoxy resin. I've never worked with aluminum so is the dent something I can gently pound out or am I better leaving it alone? If you don't have a MIG welder, take it to a welding shop, it doesn't look like it would cost much to fix. The proper way to do it is to cut a section of metal out to remove the crack, and weld in a patch. If there is a small airport near to you, you might find an A&P mechanic that could do a riveted type repair for your boat. Or if it's just a hairline crack, drill small holes on either end of the crack (to prevent it from running further) and then JBWeld both sides (holes also allow both side to connect. The rivet idea would work too, but I would patch both sides and be sure to use a rubber sealer between them for added leak protection. I have used the Alumiweld product before, typically comes with a stainless steel scraper rod, I did not use the stuff with the flux. Unless you plan to use that hole again, it would be quicker and easier to put an aluminum plate on the inside and using a TIG or MIG welder just weld it up. Not that easy as the boat has fuel tanks and fuel vapors, lots of welders will not touch it. For the patch, we cut a single piece of 745 (10 oz) Episize™ Glass Fabric for the outside and three pieces (in diminishing sizes) for the inside. Accurate Metalworks Marine offers many custom marine repair services including steel, fiberglass, and aluminum boat hull repair and transom repair.
Accurate innovates in fiberglass boat hull repair on yachts, powerboats, sailboats, catamarans, cruisers, bass boats, ski boats, pontoon boats, deck boats, runabouts, cabin boats, ships, fishing boats, bowriders, airboats, motorboats, trawlers, speedboats, or inflatables. We routinely use and make repairs to Epoxy, Polyester, and Vinyl-ester boat hulls either here in our shop, or at your docking location or shipyard. Eventually, a riveted jon boat of age will begin to leak if it gets used a lot.So, after a bit of research I found the solution.

I too, have a very leaky jon boat (1958 Quaticha) and was curious if this fixed your problem?
John Kennedy offered his old 15' Michi-Craft canoe, saying he would bring it down from his cabin at the end of hunting season. The metal had yielded, so we cut away enough of the torn edges to allow the aluminum to lie fair. Stopper holes were drilled at the end of each tear, and the surface was prepared by wet sanding with 80-grit. Working away from the canoe, we stacked up the three inner patches and squeegeed them to make sure there was no entrapped air. It looks like a limb fell on it at some point in time that left a decent dent on the edge of the hull and possibly contributed to a nearby crack in a rib. Any A+P mechanic can do this, but you can also approximate the same thing using hardware grade stuff and some good sealant. I've had pretty lousy results with it when working on things that hold water, or keep it out. The problem with soldering aluminum is the oxidation of the metal when you heat it, hence the scraper rod, or flux, I believe I used a regular Mapp torch.
Whether you're researching a new boat, or are a seasoned Captain, you'll find The Hull Truth Boating & Fishing Message Forum contains a wealth of information from Boaters and Sportfishermen around the world. John Kennedy offered his old 15′ Michi-Craft canoe, saying he would bring it down from his cabin at the end of hunting season. We work out of our shop in Palm Beach Gardens Florida, or come to you with our mobile aluminum welding and hull repair trailer.
Our methods and procedures for restructuring and reinforcing the fiberglass hull are unmatched. During our repair work, we reinforce with core material, glass and fare so your fiberglass repair is stronger than new. Most steel hull repairs are needed after an impact or a rust hole has opened under the water line.
This stuff will sit for a minute and you can wipe the paint and chemical off with a paper towel. 2nd- locating each leaky rivet by filling the boat with enough water to cover the interior floor revealedenough leaky rivets, so what the heck. Not smiling, he asked a few weeks later “just how big a repair we could handle.” It turned out John jack-knifed his utility trailer on an icy road, punching a fist-sized hole in the stern quarter of the canoe (Photo 1). Cut up and placed in the green city recycling bins, the canoe could be gone the next trash day.
A hammer and an auto-body bucking dolly gave us reasonable control in getting the hull close to its original shape. Finally, we mixed 406 Colloidal Silica with the residual adhesive in our cup to make a thickened mixture suitable for filling the holes and cutaways in the canoe (Photo 5).
We then centered the stack of patches over the hole on the inside of the hull and carefully laid it into place (Photo 7). This “toughened” fairing compound smoothed the outside for better hydrodynamics and the inside for cleanliness and additional scuff resistance.
To yacht quality standards, we routinely fix hulls with hurricane or storm damage, and patch & repair aluminum hulls.

Accurate will fix your steel boat, yacht, or ship utilizing innovation in design, longevity, and desirable seaworthy materials. From pitting, scalloping, pimpling, rust or corrosion, to the most difficult sagging or hogging, we fix your hull the right way.
When it arrived as a green stick with the real product description, it's called Scotchkote 226P made by 3M. Then, I put a wire brush on my drill and roughed up the surface around and on top of the rivets. 3rd - the boat floor is covered with Landau factory flooring and carpet - so replacing rivets was not an option I wanted to explore.
Checking the mental Rolodex for the friend with the TIG welder and the associated skill to weld such wounds in thin gauge aluminum was another option. We drilled stopper holes at the end of each tear to reduce the potential for crack propagation. Will repair Zinc based metals, (Pot Metal), Mag-Alloy and Galvanized Steel all with a propane torch. Initially, we remove damaged or corroded aluminum plates, build a precise template, cut new aluminum plates, bend as needed, replace and tack fit, then weld to U.S.
We have the expertise to recommend alternative applications to common and unique challenges with your steel hull. Our company offers boat hull repairs in and around Jupiter, Tequesta, Hobe Sound, Jupiter Farms, Juno, Palm Beach Gardens, Singer Island, North Palm Beach, Riviera Beach, West Palm Beach, Loxahatchee, and Palm Beach Shores. However, unless you are in the business of patching aluminum boats or have other uses, this stuff is sold in bulk at 5lbs.
To apply the ScotchKote, you take a propane or mapp torch and heat the area for roughly 30 seconds, and then rub the stick in a circular motion to melt the product on and around the rivet until you have a build up and can tell it's sealed good.
Or perhaps finding another friend, who is convinced that a torch and brazing rod in the hands of an artist will solve almost anything.
We then checked the outside of the hull to make sure that the pressure on the adhesive in the holes was not pushing the outer patch out of fair. Remember, aluminum conducts heat away very rapidly, so you must pour substantial heat into a wide area to get it hot enough. Furthermore, we offer you the convenience of sourcing your entire hull repair to one company.
We used a coarse 3M® Roloc™ Bristle Disc to remove paint both inside and outside, giving ourselves plenty of bonding surface area around the hole (Photos 2 & 3). When satisfied with the patch placement and fairness, inside and out, we let the patch cure overnight. I then came back with a can of camo OD Green paint and painted over all of the rivets and other touch up marks as needed.

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