Typical small boats have transoms made of wood, as the years pass the wood will rot and become useless. This instructable will guide you in removing, fabricating and replacing the transom of that old boat you just bough againt your wife's wishes.
16 - 2" stainless steel carriage bolts
32 - Stainless Steel washers
16 - lock-washers
16 - Nylon threaded stainless steel nuts
2 - pieces of extruded aluminum "L" (optional)
1 - 6oz tube of 3M 5200 Marine Sealant
1 - 8' x 4' -Â½" Pressure Treated Plywood
1 - Can of fiberglass resin (Jelly)
1 - Bondo applicator
1 - 6oz tube of Gorilla Glue
Wood Clamps (you can use any type of weight if you don't have clamps)
Drill with stepped drill bit
Total cost: around $125
Step 1: Removing the old Rivets
The first thing to do is identify all rivets that run through the transom. In my case I had 16. After identifying the rivets to remove, mark the outside of the rivet head with a black dot with a sharpie. No use drilling out a good rivet.
After marking the rivets to be drilled out get your drill and get to work. Besides replacing the rivets with carriage bolts, this is probably the most difficult task of the process. Use a spring loaded punch to start a divot on the rivet head so your drill bit doesn't go all wild. Drill the rivet head as least as possible, once you see the head is about to be drilled through, stop immediately, no use making the hole in the hull any bigger than it needs to be. Repeat this task for all of the marked rivets. When you are done, the transom should be loose and with a little coercing, be ready to be removed.