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Think it will cavitate?
 

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No sir, I'll be bringing my boat.
Here are a few more pics. He cut the boat in half and welded in an additional 22" of aluminum. That was the width of the pod he.put in with to motor on it.
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Don't know if any of these will help.

Sent from my XT1585 using Tapatalk
 
Paintman said:
I'm guessing 3m 5200 may be the way to go
I think you may be right. Wish they made an aluminum ski you could weld in. Good luck! Don't dismiss some of the flexible epoxies.
 
We bolted our pod in with 5200. Used it to seal all of the remaining areas too. The leaks we had appear to be areas where the 5200 wasn't applied at all or not thick enough.

We actually didn't have any leaks around the pod, just at all the other points.

She should be ready for another test.

Sent from my XT1585 using Tapatalk
 
Paintman, that install looks great. Shouldn't cavitate!

The 5200 is pretty runny & on my 1st install it ran out overnight, esp. at the transom vertical seams.

On my redo, I taped the seam from underneath to hold the 5200 in. I used some 1/8 plastic spacers (inboard of the caulk) to hold a consistent gap. At the transom, I taped it up both sides a couple inches at a time. I did the transom top seam separately.

I used 2 caulk cartridges of 5200, probably was overkill.

I would scuff the hull alum with 80 grit right before you do the install.

Leaks can be hard to pinpoint later!

I have mine cross-bolted to the internal bracing, so no screws go directly thru the hull.

Good luck
 
Yo Paintman, check out my latest build I just posted. I seal everything with 3M 5200 and stainless screws then come back over it with fiberglass and bondo for smoothing.
 
I also used fiberglass filler for smoothing. I recommend epoxy resin for the fiberglass filler. Polyester can absorb water & has less adhesion to boot.
 
The bondo is very small amounts, basically when the glass is laid it still creates and uneven surface so after sanding you still have high and low spots, that's where the bondo comes in. Its not large amounts to fill up huge holes. It's a given if a person smacks a huge rock, no matter whats under there on the hull, it stands the possibility of doing damage. I personally try to stay away from the rocks...lol.
 
Some more pics
 

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