Hey guys, I recently had a couple cracks in my hull welded and after 2 outings, two of the cracks opened back up and are leaking again. I'm thinking about using some JB weld or "mighty putty" or something to keep it from leaking. I'm skeptical about having it re-welded because it's already a compromised hull and I expect them to rattle loose and open again. It's a 19 foot DuraCraft with a 150 so I'm not trying to fix a little John boat.
Anyone had a similar problem and figured out a solution??

Welding is going to be the only thing that will work. If the job was done right in the first place, it should not be opening back up after two outings.

James Propeller will repair aluminum

By all means, weld it! Find you a TIG welder and have him weld it.

I've had aluminum boats for over 20 years and I've had the same problem with trying to repair cracks by welding that you are experiencing. Maybe it wasn't done right but it sure seems to happen to a lot of people. I have found the best remedy for cracks/leaks is 3M 5200 Marine Sealant. If you can get to the cracks from the inside of the hull I think it could last forever. On my boat I had to put it on the outside of the hull which is not pretty, but it is very effective. It is not a permanent fix but it lasts longer than anything I've tried. Stay away from JB Weld, it cracks after a few trips.

Usually welds will reopen / crack do to impurities. I've had the same problems in the past until I found a good welder. Contact North Trxas Fiberglass, there use to be a man that worked with them that was an aircraft welder, I believe his shop was a few doors down from theirs. Also, might check with Tiltman, he runs an aluminum rig and I think he might know of someone as well. If Gorilla Hull could just figure out aluminum boats, we would be set.

Get it welded from the inside and outside of the hull. That will do it.

Well...sounds like I'll be shelling out another couple hundred bucks to get it welded again. I'm going to find out if I can get access to the cracks from the inside. Thanks guys.

Before doing any welding make sure to drill a good hole at both ends of the crack. This will stop the crack from running.

You need to send a PM to Tiltman.

Just did.

Good grey duct tape inside and out. Works like a champ if you drill the tiny holes to stop the cracking.

Agree - the welds [if done correctly] are probably going to be stronger than the hull's aluminum skin. If there is no stress relief for the original cracks, they will continue to "run" until the stress is finally relieved.

Most of the cracks are a result of Fatigue. I think you need to look at what is causing that particular area to flex so much and add some structural integrity and reweld.

This is the direction I would go , its pancaking my guess is I need to get under the deck to see why.