Patching Sheet Metal Holes

Patching sheet metal holes using low temp solder.

Patching sheet metal holes.

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. Leave the repaired area to cool off thoroughly. The kind of plug to use depends on how the thin metal is being used. After slicing the patches out with a cutoff wheel next came the bending hammer and dolly session until the patches matched the holes and fit snug and flush into the flanged seat.

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. I then used the templates to trace out the patch panels on some sheet metal. I used a piece of pvc pipe a vice mount miniature metal break and body hammer kit. Most thin sheet metal repairs use 1 8 inch pop rivets.

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. 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. Holes in thin metal can be filled with plugs.

If you know how to weld take advantage of your tools for a longer lasting repair. Whether you re dealing with a small piece of sheet metal or something valuable like a car you can fix it. By filling in holes you stop rust in its tracks and ensure the metal lasts longer. Then build up the epoxy above the surface of the metal and let it slightly overlap the edges of the hole.

Allow the epoxy to cure. Continue melting the metal and blending the patch together with the surface of the aluminum until the hole is repaired. Step 2 weld the patch onto the aluminum with a propane torch. Apply epoxy until the hole is filled.

A power sander will speed the job. 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.

Drilling a corner hole first provides more freedom to align the sheet metal in preparation for the next hole to be drilled. The sheet metal patch should overlap onto the metal panel at least 2 inches past the edges of the damaged area.