Patching Sheet Metal Holes

If you know how to weld take advantage of your tools for a longer lasting repair.

Patching sheet metal holes. 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. Allow the epoxy to cure. Body filler is a simple way to repair freshly cleaned holes. Perhaps a simple rivet or sheet metal screw can be secured in the hole.

Whether you re dealing with a small piece of sheet metal or something valuable like a car you can fix it. If the hole needs to contain a liquid a rubber washer can go on the sheet metal screw to render it water tight. Modified on 2010 02 18 08 54 by jeff joslin categorized as restoration topics patching sheet metal holes using low temp solder. If you re patching tiny nail holes you can cover up the repairs by dabbing on touch up paint with a soft cloth.

Apply epoxy until the hole is filled. Place the patch over the hole holding it with a steel clamp. I used a piece of pvc pipe a vice mount miniature metal break and body hammer kit. Then build up the epoxy above the surface of the metal and let it slightly overlap the edges of the hole.

By filling in holes you stop rust in its tracks and ensure the metal lasts longer. Patching sheet metal holes using low temp solder. If you re patching a large number of holes and other damage prime the patched walls before repainting especially if you re choosing a semi gloss or shinier finish. Step 2 weld the patch onto the aluminum with a propane torch.

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. Continue melting the metal and blending the patch together with the surface of the aluminum until the hole is repaired. Heat the torch and start welding all around the edges. Leave the repaired area to cool off thoroughly.

Most thin sheet metal repairs use 1 8 inch pop rivets. 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. I then used the templates to trace out the patch panels on some sheet metal. Holes in thin metal can be filled with plugs.

A power sander will speed the job. The kind of plug to use depends on how the thin metal is being used.