- 1). Install a sanding attachment on a rotary tool and grip the tool tightly. Turn on the power and adjust the tool to its highest speed. Touch the textured side of the spinning sanding bit against the hull to remove any rust.
- 2). Clean the entire hull with soapy water. Rinse away the soap with clean water. Dry the boat thoroughly with soft, clean rags.
- 3). Hold an aluminum can securely in one hand. Puncture the side of the can with the tip of a razor knife and make a slit in the can. Cut around the top and bottom of the can with tin snips to make a patch. Discard the can top and bottom.
- 4). Clean the inside of the patch to remove all the sugar and other residue from the aluminum. Apply a coat of marine silicone to the hull around the damaged area. Press the patch into the silicone so it covers the hole.
- 5). Drill a 3/8-inch hole through the patch and the hull of the boat. Press the head of a rivet through the hole and squeeze the handles of a rivet gun to connect the two pieces of metal. Install a rivet every inch around the perimeter of the patch. Wipe away any excess caulk from the repair with a wet rag. Let the silicone cure overnight.
- 6). Shake a can of primer for 30 to 60 seconds. Hold the can upright and spray the primer over the patch, using long, smooth, side-to-side motions. Let the primer-covered patch dry before priming the entire hull. Let it dry overnight.
- 7). Shake a can of marine-grade paint for 30 to 60 seconds. Hold the can upright and spray, using the same side-to-side motion following the line of the hull. Apply three coat, allowing each coat to dry completely before the next application.