Easily Repair Your Aluminum Boat Holes with Super Alloy 5 and Oxyacetylene

Mike teaches Muggy Weld customer Steve (Alternative Automotive, Sarasota, FL) how to repair holes in a heavily corroded aluminum boat, using Super Alloy 5 aluminum rod and an oxyacetylene torch. ALUMINUM IS A MASSIVE HEATSINK. YOU CANNOT USE PROPANE ON ALUMINUM BOATS, THE PARENT METAL WILL NOT GET HOT ENOUGH.
When using an oxyacetylene torch, I set my acetylene to 5 PSI and the oxygen to 15 to 20.
Always keep your flame moving when working on thin aluminum. Keeping your brazing torch in one spot for too long could blow a hole through the aluminum. You can always close the hole but no need to repair another hole that could have been avoided.
Here's a tip for working with flux: heat up the rod first before dipping it into the powder. If the flux doesn't stick, you can try dipping the rod in water first, then in the flux. But if there's already flux residue on the rod, just keep reapplying the flux without using water
Clean the aluminum before brazing. The flux does clean most contaminates but don't waste the flux as a cleaner. On aluminum boats, you need to heat the surrounding area before adding the flux to your work area. Keep your flux as close to the work area as possible. This will help keep the aluminum from cooling so much between solder deposits. This was Steve's first time brazing with the Super Alloy 5, and he caught on very quickly. Usually, there is a learning curve when arc welding. TIG welding, MIG welding, and brazing aluminum. Most of the time, it will take a rod or two for someone to get how aluminum soldering and brazing works. But once you get how to braze aluminum, you won't be intimidated by thin aluminum.
To bridge a hole in an aluminum boat you can employ a couple techniques. You can work around the hole, as shown in the video, or you could build a bridge of short pieces of the rod across the hole and heat at the end. You could also back the hole with a steel plate to make it easier. The Super Alloy 1 rod can work on Jon boats or boats 14 feet and under, which can be used with a propane torch. The rod has zinc in it and is not advised if the boat will be used in saltwater.
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