I have owned four different aluminum boats myself and have experience with
problems related to corrosion.
I had a problem with the rivets on the first two I owned (both 18'
Starcraft). What was happening was a small amount of water left in the bilge
would collect in the bow area during the winter lay-up. It happens that my
typical fall fishing would include trips to salt water and I have to assume
the water in the bilge was at least somewhat salty. Anyway, the rivet ends
(peened end on inside of hull) were rotting off in this isolated area of the
hull. I actually had some pop out and it is amazing how much water can come
through a couple of 3/16" dia holes! The fix was easy after being directed
by Starcraft to a local authorized repair facility. They simply replaced all
the affected rivets. (Biggest hassle was removing the floor to access the
area - not a user friendly job!)
I also have experienced a very odd "rot" on the bottom of my third boat, a
welded aluminum hull (manufacturer will remain un-named).
After only 9 months, I had the opportunity to take a look at the bottom of
the boat while it was supported on a sling. I was shocked when I noticed
severe, for lack of a better term, "rotting" of the aluminum isolated to
those areas of the hull that are supported by the trailer bunks. The pitting
went at least half way through the 3/16" thick hull and was extensive over
two areas of approximate 5" x 7 feet. Keep in mind, this was a $15,000 hull
that wasn't even a year old!
Turns out ,although the dealer never admitted to it, the trailer was a
fault. The bunks were pressure treated lumber covered with carpeting. One of
the elements of the pressure treatment on the lumber is copper. When you
sandwich a saltwater soaked carpet between aluminum (the hull) and copper
(coming out of the bunk) you have a nice little battery. Can you spell
ELECTROLYSIS. Well, I'm not sure I can, but that's what was going on, and it
damn near ate it's way through that hull!
I went to work on the dealer and after some pretty serious conversations, he
provided me with a new boat and modified my trailer with a new type of bunk
made out of plastic. Almost two years later and no problems.
Long story - I hope you found it interesting!
Good luck!