You don’t have to worry about it cracking from working it, you can bend 5052 Aluminum without it breaking or cracking but it will stretch if you’re not careful. The riveted seam might loosen as the rivets they used are softer than the sheeting, if that happens you can re-buck or replace but you might have to use a sealer on the seam if it moves too much.
I would make a hardwood form shaped like the finished profile and put the hammer to it. A little heat will help soften it up but go easy, it makes it easier to stretch too.
Yeah, up until now it’s just been the nasty part and the hard work of tearing it down and trying not to do more damage that we will just have to fix later, I have been looking forward to getting started on the repairs where you can tell that progress is being made.
Removing the fifty plus year old paint from the bottom was a battle, we tried plastic pellets which just sort of shined the paint, we went to crushed walnut hull media which just dulled the shine the plastic created and ended up using the finest sand available which cut the paint right off but did leave a coarser finish than I would have liked but the paint had to come off. The blasting revealed numerous small holes in the bottom from the corrosion and cracks in the sheeting where the prop shaft support mounted to the bottom and a small crack in the sheeting under a stringer (I would bet the stringer above the crack is damaged). It also exposed some fairly significant damage to the transom sheeting from corrosion and significant corrosion to the cutwater at its lowest point at the front.
“There’s always more than you know”.
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Wooohhaahh, That is some serious business you guys are dealing with! My flotation foam was pretty nasty in my boats well. Luckily no mouse excrement, but bad nonetheless. I soaked mine with oxyclean laundry spot cleaner with a little bleach and rinsed. The foam looked great after that.
Oh I think everyone needs just a little whiff off the mouse pi$$ high rise condominium just to appreciate the amount of elbow grease it's going to take to get it clean enough to start the next stage of the restoration you all know when Ray blows everyone's mind with his Jedi level feathercraft skills
So Ray, let me get this straight. you removed the bulkhead to find this mountain of mice crap and goo? Wow, that's gross. I had a Merc one time with mouse nest and the smell was very very potent! I couldn't imagine the smell you guys had to endure to clean that out. Make sure you use bleach next power washing!