Aluminum Boat Barrier Coat Epoxy Primer
TotalBoat TotalBoat by Jamestown Distributors
  • Aluminum Boat Barrier Coat Epoxy Primer
  • Epoxy primer for pontoon boats

TotalBoat Aluminum Boat Barrier Coat Primer

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 as little as 3 hours at 90°F, with no sanding required.

Available in Gray (matte finish), in Quart and Gallon kits.

Bonus: Each Gallon order includes a paint roller frame, 3/16 in. nap solvent-safe roller cover, metal tray, stir stick, paint suit w/hood, & 2-in. chip brush. Each Quart order includes a stir stick & a 2-in. chip brush.

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$35.99 / kt
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Tech Spec Product Info User Generated Content
Technical Specifications  Aluminum Boat Barrier Coat 
Number of Components 
Mix Ratio by Volume  3:1 (3 parts base to 1 part curing agent) 
Application Method  Brush (natural bristle, solvent safe), roller (3/16'' nap or foam, solvent-safe roller cover), or spray (conventional, airless, or HVLP) 
Application Temperature  50-95°F; 0-85% relative humidity 
Induction Period  15 minutes (prior to reduction (optional) and application) 
Pot Life  2.5 hrs @ 90°F, 5 hrs @ 70°F, 10 hrs @ 50°F 
Number of Coats  2-3 (minimum); It's important to achieve a total of 8-12 mils DFT 
Film Thickness Per Coat  4 mils dry (7 mils wet) 
Coverage  225 sq. ft./gallon (at 7 mils wet, not accounting for waste 
Recommended Brush   For optimum results, use a high-quality brush with natural bristles 
Recommended Roller  Use a 3/8" nap solvent-resistant roller cover 
Recommended for Surface Etching on Bare Aluminum  TotalBoat Aluminum Boat Etch Wash (optional) 
Reducer/Thinner  TotalBoat Epoxy Primer Thinner 200 
Surface Prep Solvent  TotalBoat Dewaxer & Surface Prep 
Cleanup  TotalBoat Epoxy Primer Thinner 200 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 @ 90°F without the need for sanding.
  • Easy to apply by brush, roller, or spray equipment.
  • Comparable to 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
  • Color: Gray
  • Finish: Matte


Why Should I 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.

Mixing Note: 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 15 minutes prior to reduction (if needed) and application.

Application Note: 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): Yes
BRAND: TotalBoat
Material: Epoxy
Number Of Parts: Two Part
Type: Barrier Coat Primer
4.5 10

Nice and think


It went on great. I like the way it turned out. It is going to be nice bullet proof layer. I did not add brushing paint thinner. I wish I would have added a little paint thinner just so the paint wasn't so thick while working with it.

Captain Ryan



Drys quickly


Stuff is awesome. Unfortunately I couldn't cover the boat and had to paint in direct sun. My fault but didn't expect it to dry as quickly. Had my wife tipping it after I rolled it but the epoxy started to cure and started to clump. Not an issue but paint on an overcast day or thin. Went on smooth and there is probably no other paint as good as this. Would give it a 5 if it cured a bit slower.


New Jersey



This product is exactly what I was looking for as a barrier coat on an 28' aluminum boat. Applied the product per the directions and the primer has excellent adhesion, cured well and sanded well when I had to apply bottom paint at the location of the boat stands.


Middlebury, VT




My aluminum canoe was in need of paint job, first I power washed to remove all loose paint particles, sanded some rough areas and used some BJ Weld to tighten up some of the leaks. Mixed up the TotalBoat Aluminum barrier coat primer (3 to1), it all fit in the quart can, mix well. Used a foam 4" hot dog roller and rolled out the canoe hull. Let dry overnight then applied Total Boat Aluminum Finish Coat (Army Green). A week later took the canoe out into nearby lake and beaver ponds - thus dragging the canoe over logs through weedy areas. After I got home and inspected the hull, it was as if I just painted the hull - no paint scratches or scars. Paint provided excellent protection and proved to have outstanding adhesion.




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


Great Product


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.




Good Stuff....


I have been dealing with Jamestown Distributors for about twenty five years and have nothing but good to say about them.

Gary L.

Hayden, Idaho


Good product!


Good base coat!




Great product!


Very quick shipping and product performed as described.


East TN


TotalBoat Aluminum Boat Barrier Coat Primer



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