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Can Aluminum Be Welded? Boat, Pontoon & Aluminum Trailer Repairs
Why
Aluminum welds well with TIG or a MIG spool gun, but it needs clean metal, the right filler and a welder who does it regularly. That's why it costs more per hour than steel.
Old, corroded or very thin aluminum may need a patch or section replacement instead of a weld on the crack.
Fair shop price
| Job | Published price | Source |
|---|---|---|
| Aluminum TIG repair (mobile) | $120–$180/hr, $150 minimum | Greenwood Welding Repair |
| Mobile marine repairs | $175–$250/hr | Victory Customs |
| Shop TIG/MIG services | $95–$150/hr | Victory Customs |
These are published prices from the sources listed, not quotes. Your price depends on rust, access, metal type, and travel. Typical welder labor runs about $60–$125/hr nationally (HomeAdvisor).
Cost to replace instead
Depends entirely on the boat or trailer (no sourced replacement range yet).
DIY or hire a pro?
Not a beginner job. Aluminum needs AC TIG or a spool gun, very clean prep, and it gives no color warning before it melts through. Hire a pro for hulls and anything structural.
🚩 Ripoff red flags
- Welder doesn't ask what alloy, or what's behind the plate (foam, sealant, fuel).
- Welding a leaking rivet line without checking the rest of the hull.
- No pressure or leak test offered after a hull repair.
🧰 Tools & parts for this job
⚠️ This is a structural, load-bearing part. Epoxy, putty, or other DIY adhesive fixes are not safe here. Below are replacement parts and protective gear only; the repair itself should be a proper weld or a new part.
- Stainless steel wire brush (for aluminum only)Aluminum must be cleaned with a dedicated stainless brush before welding.
- Aluminum boat rivetsLeaking rivets on riveted hulls are often replaced, not welded.
- Replacement boat trailer winch strapA frayed winch strap is a cheap replacement part worth swapping at the same time.
- Trailer bunk brackets / hardwareBent bunk brackets are a cheap bolt-on replacement.
- Galvanized or stainless trailer hardware kitCorrosion-resistant hardware for salt-water trailers.
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⚠️ Safety
Fuel and foam are the danger. Remove or gas-free fuel tanks and lines before any welding near them. Flotation foam burns and gives off toxic smoke. Boats should be out of the water for hull welds unless the welder is marine-experienced.
This is general information, not an inspection. If in doubt, have it looked at in person. See our safety disclaimer.
Common questions
Can an aluminum boat be welded?
Yes, by a welder with aluminum TIG or spool-gun equipment who checks the alloy and what's behind the plate first.
Why does aluminum welding cost more?
It needs specialized equipment, spotless prep and more skill. Published rates run about $95–$180/hr, versus about $60–$125/hr for typical steel welding.
Sources
- Greenwood Welding Repair – Published Rates
- Victory Customs – Marine welding pricing
- HomeAdvisor – Welding Cost (2026)
Prices checked 2026-10-18. Ranges are updated as we find better data.