I've got an old jon boat which I'll be replacing old loose rivets on and doing some fab work to.I was wandering what type of sealant to use when putting new ones In?Also will be adding a gun box,I've read that old aluminum is prone to cracking when welded? This Will be done with a tig and some 6061 rods,Its been Awhile since I welded but feel very confident about thé Job.
Is This true about the old alu cracking?

It's going to be tough to tig anything on an old boat. Very hard to get clean. But it is possible.

Need a big hammer for a backup to beat the rivets in. I have a old rivet set that works really well.

You might can beat the old rivets a little and seal them back off.

Haven't seen old alum crack when welded. Just have to watch out for pitted areas. They can be tough to fix.


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NLH, I'm surprised you didn't tell him Flexshot

After rebucking your rivets GatorGlide would be the best way to seal them. as for welding on the old aluminum, you may consider building a removable gun box. If you were successful at welding you're going to temper the aluminum and it will probably crack. I have not seen any long term success welding old, thin probably 7075 unless it was in really good shape and the welder was really good.