I used it to plug threaded holes in an aluminum casting. For an easier, nearly-as-good fix that keeps water out and is almost invisible from several feet away, fill the hole …

im self taught at tig welding and i got aluminum down pretty good.

In theory, that material can now be re-drilled and then tapped for the screw thread you have. A long bead does two things on thin metal- puts a lot of heat into the metal, and tends to burn through the metal. Sand the patched area with a 120-grit sanding sponge until it feels smooth and even. Perhaps a simple rivet or sheet metal screw can be secured in the hole.

I've got to drill out a lot of rivets in the walls to remove various brackets and such that were installed for FedEx (but I don't need), and then fill the resulting holes. The only way to repair these holes perfectly in vinyl or aluminum is to replace the entire piece—a repair that ranges from challenging in vinyl to almost impossible in old aluminum. The holes are 1/4-inch diameter, I believe three holes, below the waterline. whats the best way to go about filling in a hole?

The [previous owner] had drilled holes below the waterline for senders.

The procedure to fill holes in a metal door is similar to repairing wood doors. You could fill the hole completely, using an aluminum "welding" material. The kind of plug to use depends on how the thin metal is being used. Aluminum siding used to be all the rage some 25 years ago, but now the more modern vinyl siding has followed in its footsteps.

The color is enough different from aluminum that it is obvious. Filling Screw Holes with Thickened Epoxy Andy Miller of the Boatworks Today YouTube channel is back on board his Bertram Moppie today with some advice about how to best fill old screw holes that either need to disappear or might be better off re-drilled and reset. Learn how to repair aluminum siding and patch holes both big and small! I would weld them shut and then finish them by grinding and sanding them later. This easy-to-use filler can be drilled, filed, sanded and painted and forms a long-lasting, metal-tough bond.

Aluminum siding used to be all the rage some 25 years ago, but now the more modern vinyl siding has followed in its footsteps. Rust is an inevitability with metal, but that doesn't make it less shocking when you walk out and see a hole forming. I coned out the topside of the hole with a drill bit first so there is … Stick it on and mud it smooth. Holes in thin metal can be filled with plugs. The process of welding to fill trim holes is done with stitch welding.

The difference is the type of filler that you use.

Re: what is the best way to fill small holes in aluminum?

I probably have some water intrusion, but right now I just want to fill the holes.

Discussion in 'Metal Boat Building' started by Katoh, Mar 12, 2011.

We also center bore the hub of the rim to fit vehicle. The foregoing not withstanding, aluminum siding is a singularly durable exterior product, and those whose homes are ensconced are loath to give it up. Fortunately these holes are fairly easy to patch and repair using epoxy resin fillers designed for automotive bodies. Sorry this picture is titled, website wont let me rotate it. -Sanded around the holes-Cleaned out the mysterious dust-like material, no idea what it is-Mixed hardener & filler in an old frisbee-Used a spreader to fill … Permatex Liquid Metal Filler is a specialty adhesive which offers ideal solutions for many automotive bonding jobs. When in doubt, fill it, sand it, then fill … It did bond well. Recently bought a used Grumman P30 step van, it's body is a big square box made from aluminum. I have heard if you place a piece of copper or brass plate on the other side of the hole while welding you can fill the hole with a half decent finish already to that side.

My Nassau had more holes and dings than I could count. Stitch welding alleviates those problems by allowing the metal to cool between welds. The only way to repair these holes perfectly in vinyl or aluminum is to replace the entire piece—a repair that ranges from challenging in vinyl to almost impossible in old aluminum. It appears that the holes were just filled with silicone or caulking.