Aluminum Boat Repair, Refits and Repowers
Some boats are worth rebuilding. We take on the big projects.
- 3D laser scanning
- In-house CAD
- Repowers and conversions
- Collars, cabins and fuel systems
- Vessels up to 100′
ARMOR takes on major aluminum boat repair and refit projects: inboard-to-outboard conversions, offshore brackets, collar repair and replacement, fuel systems, cabins and structural rebuilds. We 3D-scan the boat, design the work in-house and build it in our Anacortes shop, the same way we build new boats.
We focus on large refits for commercial, government and private boats. For small repairs and routine service, a local service yard will be faster.
Is your project a fit?
We take on
Major repowers and conversions, structural repairs and rebuilds, and full refits for commercial, government and private boats.
We don't take on
Small repairs or routine service. For those, a local service yard will be faster and cheaper.
Rates
| Rate | |
|---|---|
| Shop | $165/hr |
| Field | $195/hr |
| 3D scanning and in-house CAD | $225/hr |
| Minimum | $3,500 per project |
How we do it
1 · Scan
A high-resolution 3D laser scan of the whole boat captures every surface to within 1/8″, so new work is designed to the boat as it really is.
2 · Design
We model the new work in CAD right on the scan: brackets, structure, tanks, collars and accessories, checking buoyancy, weight and space before any metal is cut.
3 · Cut
Plate is CNC-cut straight from the model, so new parts fit the boat and less time goes into fitting.
4 · Build it in
New structure is welded into the existing structure with tie plates that spread the load, for strength and for how the boat runs.
5 · Rig and test
Systems, wiring and rigging, then sea trials.
In the shop now: a twin-outboard conversion
A collared aluminum pilothouse boat coming off its old inboard engine. We scanned the whole boat, then designed every part of the refit against the scan. The images below are the 3D scan and the CAD model, not photos. Photos of the finished boat are coming soon.
The work
- Offshore bracket
- A new bracket for twin 300 hp outboards, sized for buoyancy and tied into the existing structure.
- Plate
- Bracket in 1/4″ 5086 aluminum, with a 1/2″ 5086 transom plate.
- Access
- A large access hatch in the center of the bracket deck.
- Fuel
- A new 215-gallon aluminum fuel tank in the old engine space.
- Collar
- A new collar.
- Tender
- A tender mount and davit.
Past project: a research catamaran back in service
The Washington Department of Fish and Wildlife brought us a research catamaran that was underpowered, under-jetted and out of service for years. It barely made 2 knots and had to be trucked to our shop.
We built a detailed CAD model, took out the old engines, cut off the stern and rebuilt it around new outboard bracket pods with a center boarding platform and ladder. New aluminum tanks and fuel system, a new deck and catwalk, rewiring, a refurbished cabin, a dive ladder and twin 300 hp outboards finished the job, and it passed inspection.
It left the shop by travel lift and ran better than ever in testing on the water off Anacortes.
What we take on
Repowers and conversions
Inboard or sterndrive to outboard, offshore brackets and engine wells, waterjet repowers, diesel engine systems. Engines through our sister company, ARMOR Power Systems.
Structure
Transom replacement, hull repair and structural rebuilds, new decks.
Collars
Repair or replace collars.
Cabins and top houses
New or rebuilt.
Fuel
New aluminum tanks and fuel systems.
Systems
Electrical, controls and monitoring, systems integration and rigging.
Fabrication
Custom modifications, davits and tender mounts, rails and towers, CNC press-brake forming.
Repowering?
Our sister company, ARMOR Power Systems, an authorized John Deere marine engine and Suzuki Marine dealer, works out of the same Anacortes shop: engine selection, supply, parts and service for commercial and patrol boats. We do the fabrication: brackets, engine wells, fuel systems and structure. One shop, one project team.
Questions about refits
Do you do small repairs?
No. We focus on large refits and major repairs. For small jobs and routine service, a local service yard will be faster and cheaper.
What are your rates?
Shop $165/hr, field $195/hr, 3D scanning and in-house CAD $225/hr, with a $3,500 minimum per project.
How do I start?
Send a few photos and tell us what you want the boat to do when it's done. We'll tell you if it's a fit and how we'd approach it.
Can you haul my boat?
Larger boats are hauled out in Anacortes and brought to our shop by travel lift; the 40′-tall doors let the lift drive straight in. We have room for vessels up to 100′.
Do you work on boats you didn't build?
Yes. The RB-S boats and the research catamaran on these pages were both built by other yards.
Tell us about your boat and the project
We design every boat in-house, so we can build to your exact requirements and help you solve the technical problems a catalog boat can't.
Prefer to talk it through?