TotalBoat Aluminum Boat Barrier Coat creates a water-tight moisture barrier to protect aluminum hulls & pontoons from corrosion, fill small imperfections & ensure a solid foundation for antifouling paints or 1 & 2-part topside finishes.
This 2-part, high-build epoxy primer features anti-corrosive properties ideal for protecting underwater metals like lead, bronze, cast iron, stainless & aluminum. Its 3:1 mix ratio is easy to measure, mix & apply. Aluminum Boat Barrier Coat dries quickly and can be overcoated in 3 hours at 75°F, with no sanding required.
Available in Quart and Gallon kits.
Bonus: Each Gallon order includes a paint roller frame, 3/8 in. nap solvent-safe roller cover, metal tray, stir stick, paint suit w/hood, 2-in. chip brush & a pr. of latex gloves. Each Quart order includes a stir stick, 2-in. chip brush & a pr. of latex gloves.
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Aluminum Boat Barrier Coat
Number of Components
Mix Ratio by Volume
3:1 (3 parts base to 1 part curing agent)
Brush, roller, or spray
50-95°F; 0-85% relative humidity
20 minutes (prior to reduction (optional) and application)
Number of Coats
Film Thickness Per Coat
2 mils dry (10 mils total)
Estimated coverage 2 mils dry thickness per coat is 400 sq. ft. per gallon
For optimum results, use a high-quality brush with natural bristles
Use a 3/8" nap solvent-resistant roller cover
Recommended for Surface Etching on Bare Aluminum
TotalBoat Aluminum Boat Etch Wash
TotalBoat Special Brushing Thinner 100, no more than 10%
Surface Prep Solvent
TotalBoat Dewaxer & Surface Prep
TotalBoat Special Brushing Thinner 100 or TotalBoat Dewaxer & Surface Prep
Creates a moisture-resistant protective barrier against corrosion on aluminum hulls, pontoons, and underwater metals.
High-build formula fills small imperfections.
Serves as an excellent tie coat that provides maximum adhesion for antifouling bottom paint or other 1-part and 2-part paints.
Easy to use, with a simple 3:1 mix ratio that ensures great results.
Dries quickly and can be overcoated in as little as three hours @ 75°F without the need for sanding.
Easy to apply by brush, roller, or spray equipment.
Compare to Pettit Aluma Protect, Interlux Interprotect 2000E, and other high-build marine epoxy barrier coatings.
Product Sizes, Color, and Finish
Size: Each Quart Kit includes 1 quart base component & ½ pint of curing agent
Size: Each Gallon Kit includes 3/4 gallon base component & 1 quart of curing agent
Average Dry Time: At 75°F, Aluminum Boat Barrier Coat dries to the touch in about 2 hours.
Recoat Time (Aluminum Boat Barrier Coat over Aluminum Boat Barrier Coat): 3-48 hours @ 75°F
Overcoat Time (Antifoulant over Aluminum Boat Barrier Coat): 5-7 hours @ 75°F
Overcoat Time (Non-antifoulant or Topside Paint over Aluminum Boat Barrier Coat): Allow 48 hours to dry. Sand with 320-grit sandpaper. Remove residue with TotalBoat Dewaxer & Surface Prep.
Why Do I Need to Etch My Aluminum Boat Before Priming and Painting?
Getting primer or paint to stick to aluminum is very difficult, and it's a tedious process that typically entails sanding with very coarse sandpaper or blasting down to shiny, bright metal followed by priming with a specialty primer. The zinc chromate primers commonly used in the past are expensive, and less widely available now due to environmental restrictions. It's also not good for painting underwater metals, because zinc is the stuff of sacrificial anodes!
You can certainly still get excellent results with primer and paint, but the secret lies in etching the surface with the right product. Compare TotalBoat Aluminum Etch Wash to Alodine or Alumiprep 33. Our phosphoric acid-based etching wash is easy to use and works fast to create the toothed surface required for epoxy primer or paint to bond effectively and durably.
IMPORTANT: For best results coating aluminum, if using TotalBoat Aluminum Boat Etch Wash during surface prep, dry the surface completely and apply Aluminum Boat Barrier Coat within 1 hour after metal preparation.
Combine base and activator components in a 3:1 ratio. If you want to mix the entire contents of both cans, just dump the can of curing agent into the can of base. There's enough room in the larger can to hold all the content of both components. Mix thoroughly, then induct for 20 minutes prior to reduction (if needed) and application.
If applying antifouling paint over Aluminum Boat Barrier Coat epoxy primer, apply antifoulant while the primer is tacky to the touch. Do the thumbprint test—touch the barrier coat with your thumb. If the primer doesn't stick to your thumb, but you can make a thumbprint, you are within the overcoat window for applying antifouling paint. If you can't leave a thumbprint, you've missed the overcoat window. Sand with 80-grit sandpaper or apply another coat of Aluminum Boat Barrier Coat. Use the thumbprint method again before applying antifouling bottom paint.
Below Water Line (yes/no):
Number Of Parts:
Barrier Coat Primer
Are there any off the shelf reducers for this product?
TotalBoat Special Brushing Thinner 100 is the brushing reducer, and Xylene (Xylol) is for spray. DO NOT use mineral spirits, acetone, lacquer thinner, or denatured alcohol as a reducer for this product. As far as off the shelf product goes, Xylene would be the easier of the two to find but it will evaporate rather quickly, and though it reduces it, it will not give it the same self leveling characteristics if used in a brushing/rolling application. Also, be careful, some solvent blends that you can find at a hardware store may contain Xylene, but other solvents in the blend that may have very poor effects on Aluminum Boat Barrier Coat.
JD Tech Associate
once mixed how long is it good for sealed?can I do several coats of it?
Though this product will appear to cure faster in a thin film rather than a mass, it is a chemical reaction and sealing it will not slow the rate of cure. Aluminum Boat Barrier Coat has roughly 2-5 hours of pot life depending on conditions. We recommend 3-5 coats depending on how thick it is applied (should reach 10 mils dry film thickness for a proper barrier coat).
JD Tech Associate
Will this work over gluvit, on an aluminum hull? Do I need to use the gluvit? Or will this seal it enough? I have a few rivets that weep?
Yes this will more than do the job of gluvit, I have used both, this stuff is very thick when you put it on properly. Gluvit goes on the inside of the boat, this is for the outside, you probably will not need gluvit once you put this on.
I would use the Gluvit which will seal any leaks, you can paint over the Gluvit.
JD Tech Team
I would not buy this again
This product came as thick as mud.I tried to thin it and it would not stick to the bare aluminum.A rep. sent me a can of Primocon.That worked well.
Can't say enough about this product.
Anyone with experience in two part poly primers would be hard pressed to find one that compares to Total Boat Aluminum Barrier Coat. I have been using this product to restore a 1963 Lone Star aluminum boat and am impressed with it's ease of use, coverage, and most of all its adhesion properties. This stuff sticks to aluminum like the military grade epoxies I used during my time in the Coast Guard. As long as you prep your surfaces properly, you can't go wrong. Wear a respirator when applying, as it is quite potent. A standard 3/8 nap roller does the trick, just burn off the loose nap prior to applying. Thanks for a great product Jamestown!
Plant City, Florida
This is a wonderful barrier coat primer that reminds me of the Mare Island Systems Epoxy Polyamide we used in the military. Easy to apply by roller, (don't use foam rollers though, it will destroy them), and lays down smooth. A gallon goes a long way if you only mix it in small batches. You will need to stir your parts for quite some time prior to mixing for best result. Use this in a well ventilated area, and wear respiratory protection as it is quite powerful from a fume perspective. This was my first experience with Total Boat and I am more than happy with the result. I would highly recommend this primer to anybody who is doing an aluminum boat restoration project.
I have been dealing with Jamestown Distributors for about twenty five years and have nothing but good to say about them.
Good base coat!
Very quick shipping and product performed as described.