Sheet Metal Hole Patch

Using lineman s pliers the plug is cut to shape slowly snipping into a circle.

Sheet metal hole patch.

Then spread the patch out so it s flat against the remaining metal. This 29 piece kit includes sheet metal patches in several conventional hole sizes. When i got to where it fit i pressed it into the hole using the same pliers. I used a piece of pvc pipe a vice mount miniature metal break and body hammer kit.

The most permanent repair to a hole in sheet metal is to weld the hole shut. Check out how you can repair rusted sheetmetal by using patch panels as shown on this 1969 camaro. Reach underneath the metal if you re able to or push the patch through the hole. For thicker sheet metal an old copper penny might be a quick source of material.

Heat the torch and start welding all around the edges. A power sander will speed the job. Insert the metal patch behind the hole. Weld the patch onto the aluminum with a propane torch.

Then build up the epoxy above the surface of the metal and let it slightly overlap the edges of the hole. The welding process actually adds new steel to the thin steel and can result in a repaired spot that is stronger than the original metal. The patch itself is slightly undersized to allow it to fit cleanly into the hole however the real icing on the cake is the tabs surrounding each circle. Keep it stuck in place by spreading a little bit of the body filler around its edges.

Leave the repaired area to cool off thoroughly and to cure. Then use 80 grit sandpaper followed by 200 grit or 300 grit to make the patch glass smooth. And butt up to the edges of the hole. Apply epoxy until the hole is filled.

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. Easy to do and really strong. I then used the templates to trace out the patch panels on some sheet metal. Best deal on goodyear air hose check this out https amzn to 3b5cjvy how to fix a hole without welding no warping.

Allow the epoxy to cure. The patch should completely cover the hole. The complexity of welding increases as the thickness of the material decreases. Continue melting the metal and blending the patch together with the surface of the aluminum until the hole is repaired.