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I am just curious if anyone has seen or heard of a weld breaking on an aluminum boat running in some swells or chop?

Local welders have fixed several Xpress and G3's. I have seen Welbilts broken also. I have owned a Tracker and Seark that were broke when I bought them.

Yes, but never so much as to make them dangerous.

I have broken the welds on both side seems on mine but then, I do "or used to anyways" run WOT out to the Groupers in mine it took a good beating most every time

Wevans is that boat still alive?

my Xpress has never leaked, but it isn't a tunnel with 90 degree welds. Anyone who rides with me will tell you it isn't b/c I'm afraid of rough water or don't run hard on tourney day. That being said, welds can break.

Any boat has some flex and over a period of time and enough flexing something will break.

AIRCRAFT THAT HAVE MANY HOURS ON THEM WILL HAVE WHAT WE CALL STESS CRACKS IN THE ALUM. SKIN AS WELL AS SOME OF THE SPARS AND RIBS. THEY ARE VERY DANGEROUS IN AIRCRAFT , I WOULD NOT THINK THIS WOULD BE THE CASE WITH A BOAT UNLESS YOU LET THE CRACKS GET TOO LARGE. THEY CAN BE WEILDED BACK LIKE NEW WHICH IS NOT THE CASE WITH AIRCRAFT.
PA
SEMPER FI

Yep Redbelly, it got rewielded and hasn't broken since then