How to Prepare Your Boat for Welding Services: A Comprehensive Guide

There is nothing like the look of a freshly polished hull. But for many captains, a day of detailing turns into a day of discovery. You are buffing the transom or the T-top legs, and suddenly—you see it. A hairline crack in the aluminum.

If you take pride in your vessel’s appearance, you need to take that same approach to its structural repairs. Here is how to transition from "Polishing Mode" to "Repair Prep" so we can fix it right.

1. The Discovery (Polishing & Inspection)

The man in the photo above has the right idea. Polishing isn't just about shine; it's about inspection. When you are inches away from the surface, you spot the corrosion bubbling under the paint or the stress fracture developing near the engine mount.

Pro Tip: If you find a crack while polishing, mark it immediately with blue painter's tape. It can be surprisingly hard to find that same hairline fracture once the welder arrives.

2. Strip the Wax (The Prep)

Here is the irony: The wax and polish that protect your fiberglass are the enemy of welding.

Aluminum TIG welding requires hospital-grade cleanliness. If there is wax, ceramic coating, or heavy compound near the weld zone, it will contaminate the puddle and weaken the repair.

• Degrease: Before we arrive, use a strong solvent (like acetone) to strip the wax off the immediate repair area.
• Don't Polish the Crack: If you see a crack, don't buff over it. You might force compound into the fracture, which makes it harder for us to clean and weld.

3. Clear the Zone

Welders need room to work. If we are welding a T-top, remove the canvas, electronics, and cushions. If we are working in the bilge, clear out the batteries and pumps if possible. The more access we have, the cleaner the final weld will be.

4. The Finish Line

Once the wax is stripped and the welding is done, we bring the finish back to the level of the rest of your boat. Whether it's a re-spray or a powder coat, our goal is to make the repair invisible.

The image above is the standard we aim for. A flawless, watertight finish that looks better than the day it left the factory. Keep polishing your boat—it’s the best way to catch problems early—and call us when you need the metal to match the shine.