Best way to fill threaded holes in aluminum spars? - SailNet Community

   Search Sailnet:

 forums  store  


Quick Menu
Forums           
Articles          
Galleries        
Boat Reviews  
Classifieds     
Search SailNet 
Boat Search (new)

Shop the
SailNet Store
Anchor Locker
Boatbuilding & Repair
Charts
Clothing
Electrical
Electronics
Engine
Hatches and Portlights
Interior And Galley
Maintenance
Marine Electronics
Navigation
Other Items
Plumbing and Pumps
Rigging
Safety
Sailing Hardware
Trailer & Watersports
Clearance Items

Advertise Here






Go Back   SailNet Community > On Board > Gear & Maintenance
 Not a Member? 
  #1  
Old 06-30-2009
BELLATRIX1965's Avatar
Maine Member
 
Join Date: Jan 2007
Location: Penobscot Bay Maine
Posts: 176
Thanks: 0
Thanked 0 Times in 0 Posts
Rep Power: 8
BELLATRIX1965 is on a distinguished road
Best way to fill threaded holes in aluminum spars?

Greetings all:

I would appreciate any suggestions regarding permanently filling no-longer-used threaded holes in aluminum masts and booms? The boat is 40 years old, and many hardware items have been removed / upgraded over the years. The aluminum is pretty thick (1/4" +-) and most holes have the threads intact. I'd like to clean it up (flush would be really nice) before a full re-paint of the spars.
Thanks in advance, and think SUNSHINE (been raining here in Maine for weeks!)!
Reply With Quote Share with Facebook
  #2  
Old 07-01-2009
Member
 
Join Date: Jun 2009
Posts: 38
Thanks: 0
Thanked 0 Times in 0 Posts
Rep Power: 0
OhioTom is on a distinguished road
Unless you can weld aluminum, I'd screw a piece of stainless steel threaded rod or stainless steel bolt into the hole with some red loctite on the threads, cut it as flush as you can with a cutting wheel (dremel), then file/sand it fair.
Reply With Quote Share with Facebook
  #3  
Old 07-01-2009
poopdeckpappy's Avatar
Senior Member
 
Join Date: Jul 2006
Location: San Diego
Posts: 5,711
Thanks: 25
Thanked 39 Times in 33 Posts
Rep Power: 10
poopdeckpappy has a spectacular aura about poopdeckpappy has a spectacular aura about
If your spars aren't riddled with holes, maybe something as simple as alu...alumanam.......alumenum........ pop rivets of the same material

can't say suspagetti either
__________________
1978 Tayana 37

Freedom comes when you’re ready to sail away. True freedom comes when you don’t have to return


Cut off from the land that bore us, betrayed by the land we find, where the brightest have gone before us and the dullest remain behind, .......but stand to your glasses, steady,.......tis all we have left to prize, raise a cup to the dead already, hurrah for the next that dies
Reply With Quote Share with Facebook
  #4  
Old 07-01-2009
Member
 
Join Date: Aug 2004
Location: CT / St John USVI
Posts: 30
Thanks: 0
Thanked 0 Times in 0 Posts
Rep Power: 0
Windborn is on a distinguished road
BELLATRIX1965,

I had the same issue with our boat. You can order various sizes of aluminum threaded rod from McMaster Carr. I put some locktite on the threads, screwed it in about 1/4" then cut of the rod. A bit of sanding and some paint, and you'll never know the holes were there. Just don't allow too much of the rod to stick out on the inside of the mast, or you might create a snag for your halyards.
Reply With Quote Share with Facebook
  #5  
Old 07-01-2009
j34035's Avatar
"Sparkie"
 
Join Date: Nov 2006
Location: Jackson, Missouri
Posts: 343
Thanks: 1
Thanked 1 Time in 1 Post
Rep Power: 8
j34035 is on a distinguished road
I repainted the mast and boom on my boat a couple of years ago. When I removed the unwanted hardware, I used a small grinding burr to clean the inside of the holes the used a counter sink to widen the opening. After that, I used a polyester body filler and simply filled and faired the holes. Awlgrip paint and you never know the holes were there.
DD
__________________
Doug
Jboat J/37c (new to me Jan 2011); J/22 #1003


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Reply With Quote Share with Facebook
  #6  
Old 07-01-2009
sailingdog's Avatar
Telstar 28
 
Join Date: Mar 2006
Location: New England
Posts: 43,291
Thanks: 0
Thanked 11 Times in 11 Posts
Rep Power: 13
sailingdog is just really nice sailingdog is just really nice sailingdog is just really nice sailingdog is just really nice sailingdog is just really nice
Filling the holes with a thickened epoxy or epoxy putty is probably your best solution. OhioTom's suggestion is unwise, since stainless steel will have galvanic corrosion issues with aluminum and may lead to future issues.

Windborn's idea is a good one, but far more work with little advantage over using an epoxy putty.
__________________
Sailingdog

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Telstar 28
New England

You know what the first rule of sailing is? ...Love. You can learn all the math in the 'verse, but you take
a boat to the sea you don't love, she'll shake you off just as sure as the turning of the worlds. Love keeps
her going when she oughta fall down, tells you she's hurting 'fore she keens. Makes her a home.

—Cpt. Mal Reynolds, Serenity (edited)

If you're new to the Sailnet Forums... please read this
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
.

Still—DON'T READ THAT POST AGAIN.
Reply With Quote Share with Facebook
  #7  
Old 07-01-2009
14432's Avatar
Senior Member
 
Join Date: Oct 2006
Location: North Carolina
Posts: 191
Thanks: 0
Thanked 0 Times in 0 Posts
Rep Power: 8
14432 is on a distinguished road
If your spar is painted white or clear anodized - Marine Tex comes in both white and gray so you may not even neeed to paint.

On that note - has anyone ever tried to color white Marine Tex with gelcoat coloring agents?
Reply With Quote Share with Facebook
  #8  
Old 07-01-2009
sailingdog's Avatar
Telstar 28
 
Join Date: Mar 2006
Location: New England
Posts: 43,291
Thanks: 0
Thanked 11 Times in 11 Posts
Rep Power: 13
sailingdog is just really nice sailingdog is just really nice sailingdog is just really nice sailingdog is just really nice sailingdog is just really nice
I would be hesitant to do that, as it may affect the epoxy's adhesion. Of course, you could always call the manufacturer and ask them.
Quote:
Originally Posted by 14432 View Post
If your spar is painted white or clear anodized - Marine Tex comes in both white and gray so you may not even neeed to paint.

On that note - has anyone ever tried to color white Marine Tex with gelcoat coloring agents?
__________________
Sailingdog

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Telstar 28
New England

You know what the first rule of sailing is? ...Love. You can learn all the math in the 'verse, but you take
a boat to the sea you don't love, she'll shake you off just as sure as the turning of the worlds. Love keeps
her going when she oughta fall down, tells you she's hurting 'fore she keens. Makes her a home.

—Cpt. Mal Reynolds, Serenity (edited)

If you're new to the Sailnet Forums... please read this
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
.

Still—DON'T READ THAT POST AGAIN.
Reply With Quote Share with Facebook
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

 
Posting Rules
You may post new threads
You may post replies
You may post attachments
You may edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On


Similar Threads
Thread Thread Starter Forum Replies Last Post
Coupling wiring to aluminum spars pdqaltair Gear & Maintenance 11 04-03-2009 05:23 PM
Stripped out threaded holes in deck kip Gear & Maintenance 4 07-10-2008 09:28 PM
Upgrading Spars Tom Wood Gear and Maintenance Articles 0 12-01-2003 07:00 PM
Upgrading Spars Tom Wood Cruising Articles 0 12-01-2003 07:00 PM
Drilling and Filling Holes in Your Boat Sue & Larry Gear and Maintenance Articles 0 03-11-2003 07:00 PM


All times are GMT -4. The time now is 08:33 PM.

Add to My Yahoo!         
Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2014, vBulletin Solutions, Inc.
SEO by vBSEO 3.6.1
(c) Marine.com LLC 2000-2012

The SailNet.com store is owned and operated by a company independent of the SailNet.com forum. You are now leaving the SailNet forum. Click OK to continue or Cancel to return to the SailNet forum.