Patching Sheet Metal Holes

Drilling a corner hole first provides more freedom to align the sheet metal in preparation for the next hole to be drilled.

Patching sheet metal holes. Then build up the epoxy above the surface of the metal and let it slightly overlap the edges of the hole. Body filler is a simple way to repair freshly cleaned holes. By filling in holes you stop rust in its tracks and ensure the metal lasts longer. Step 2 weld the patch onto the aluminum with a propane torch.

The sheet metal patch should overlap onto the metal panel at least 2 inches past the edges of the damaged area. If the hole needs to contain a liquid a rubber washer can go on the sheet metal screw to render it water tight. Introduction using the same tools and techniques as sweat soldering copper pipe this is the best way i know of doing a permanent almost invisible. Leave the repaired area to cool off thoroughly.

I used a piece of pvc pipe a vice mount miniature metal break and body hammer kit. The kind of plug to use depends on how the thin metal is being used. After the sheet metal patch has been cut and fit to size round the corners of the patch with a file or emery cloth to prevent any sharp corners from becoming a catching spot for snow or ice. Perhaps a simple rivet or sheet metal screw can be secured in the hole.

Patching sheet metal holes using low temp solder. Most thin sheet metal repairs use 1 8 inch pop rivets. Place the patch over the hole holding it with a steel clamp. If you re patching tiny nail holes you can cover up the repairs by dabbing on touch up paint with a soft cloth.

Whether you re dealing with a small piece of sheet metal or something valuable like a car you can fix it. Heat the torch and start welding all around the edges. Allow the epoxy to cure. If you know how to weld take advantage of your tools for a longer lasting repair.

A power sander will speed the job. Continue melting the metal and blending the patch together with the surface of the aluminum until the hole is repaired. Holes in thin metal can be filled with plugs. Modified on 2010 02 18 08 54 by jeff joslin categorized as restoration topics patching sheet metal holes using low temp solder.

Sanding the patch use rough about 40 grit silicon carbide sandpaper to reduce the built up dry epoxy to the level of the surrounding metal. Apply epoxy until the hole is filled.