replacing transom, has anyone used AL square tube instead of wood?

SOL III · Mar 12, 2025

has anyone used aluminum square tube welded together instead of the wood? i will be replacing my transom on 1982 18' StarCraft mariner CC. I was thinking of pourable fix, or wood but i never want to deal with rot again so it though aluminum square tube welded together, is there any experience on doing this or am I crazy?

racerone · Mar 12, 2025

I have used ordinary plywood to replace " beaver puke " found in some older boats.-----However the project ( Action Marine 17 ) I am working on for the past few summers is different.------I have used about 25 composite hollow rectangular tubes ( hockey sticks ) to rebuild the transom.-----Want the grandson to say-----" It will never rot again , thank you "----Years from now.-----So yes I think aluminum bonded properly might work.------But have you considered the different expansion rates of aluminum verses fiberglass?----Heat and extreme cold may be a factor in bonding the aluminum to fiberglass, I think.

SOL III · Mar 12, 2025

aluminum boat so rate of expansion is no concern, did you stack tubes Horizontal or Vertical? I would be welding them together.
might not be the cheapest fix but I would really like a permanent fix.

racerone · Mar 12, 2025

Tubes were bonded in horizontally using epoxy.----Luckily I got the sticks for free.----To buy new sticks would be $60 each or more.----Aluminum tubing would work.----Is your present transom 100% flat?----Slightly curved ?

Mc Tool · Mar 12, 2025

racerone said:
Tubes were bonded in horizontally using epoxy.----Luckily I got the sticks for free.----To buy new sticks would be $60 each or more.----Aluminum tubing would work.----Is your present transom 100% flat?----Slightly curved ?

yeah free is good . I have access to 2m ( 6.56') lengths of 40x40mm (1.574" ) galvanised steel tube 2.5mm (.0984" )wall thickness that comes in shipping containers ( used to stop 1 ton bags of fert leaning against the inside of the doors and jamming them closed , about 30 per container ) . Everything round here is made out of them

Scott Danforth · Mar 12, 2025

SOL III said:
has anyone used aluminum square tube welded together instead of the wood? i will be replacing my transom on 1982 18' StarCraft mariner CC. I was thinking of pourable fix, or wood but i never want to deal with rot again so it though aluminum square tube welded together, is there any experience on doing this or am I crazy?

Wood lasted 40 years

Use wood
Or coosa
Or other approved transom material

cyclops222 · Mar 13, 2025

Welding boat Aluminum boats requires a EXPERIENCED Aluminum welder. Or a lot of epoxy to fill some burn out holes.

SOL III · Mar 14, 2025

racerone said:
Tubes were bonded in horizontally using epoxy.----Luckily I got the sticks for free.----To buy new sticks would be $60 each or more.----Aluminum tubing would work.----Is your present transom 100% flat?----Slightly curved ?

completely flat.

racerone · Mar 14, 2025

No issue then.-----What are you going to use to bond the tubing to the transom.-----How do you plan to deal with possible warping as tubes are welded together into a " wide board " ??----Have you looked into aluminum extrusions ( scaffold planking ) to make a structure with minimal welding ?

rolmops · Mar 14, 2025

I think It would be a lot cheaper and better looking if you use properly treated marine ply. If you treat it the proper way and give it a lick of paint every few years, it can easily last for 40 years.

SOL III · Mar 20, 2025

after the sticker shock eased, I'll be doing a wood replacement.
wont last as long but it will outlast me.

Fj40fiji · Jun 16, 2025

I did it, 2x3" Al tubing rig welded into a frame that was then welded into the transom of my 14' Klamath dlx. It was over kill, but when I sold it the buyer was awestruck with it and didn't negotiate the sale price from what I had advertised. I wouldn't do it again, it was more work than it was worth even though I only had to pay for the filler rod and gas.

drewm3i · Saturday at 6:41 AM

rolmops said:
I think It would be a lot cheaper and better looking if you use properly treated marine ply. If you treat it the proper way and give it a lick of paint every few years, it can easily last for 40 years.

It can last practically forever if one properly seals all edges and drilled holes with epoxy! Contrary to iboats opinion, boats don't just rot with great care but from misuse and abuse.

rolmops · 2025-06-22T17:06:51-0600

I do not think that there is such a thing as I-Boats opinion, The rotting within fifteen years as mentioned before is a thing that can be seen in many places. It is because because people buy boats, only to find out that it is not plug and play and they are not interested in the care taking. Add to that life as it happens. Babies are born, jobs get lost and there is less time and motivation to properly take care of all the little things that salt water does to a boat.
It is the perfect hobby for well to do retired people

replacing transom, has anyone used AL square tube instead of wood?

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