What Can I Use To Repair A Small Hole In Thin Aluminum

I'one thousand working on a car with aluminum doors and an aluminum torso lid. The doors take holes in them from a previous repair and the trunk lid has holes from a non-original luggage rack. I'm going to attempt to fill these in with my tig welder and some aluminum filler rod. Before I exercise, I'thou wondering if anyone has an easier method or helpful hints on filling them. I've never worked with aluminum this thin and I'k worried most the holes and surrounding metal getting besides hot and opening up larger than they are. Does anyone take experience with this sort of affair? Any input is appreciated.

Thank you,
Greg

Trying to fill up holes with only welding rod is not going to be fun or easy. It would be easier to become some aluminum sheet of like thickness and to cut out plugs to weld in. If you lot go this road, just be certain to become a weldable alloy such equally 3003, 5052, or 6061. Avoid any 2024 sheet you might run beyond as it does not weld well.

Harry Phinney

If the holes are small 1/4'' or so it should be a slice of cake to fill them with TIG.Holes over a 1/2'' or so you might want to add some patch material,Mike

Quote Originally Posted by shrunken66stroker

I'm working on a car with aluminum doors and an aluminum trunk chapeau. The doors accept holes in them from a previous repair and the body lid has holes from a non-original luggage rack. I'thou going to attempt to fill these in with my tig welder and some aluminum filler rod. Before I practice, I'm wondering if anyone has an easier method or helpful hints on filling them. I've never worked with aluminum this thin and I'm worried about the holes and surrounding metal getting besides hot and opening up larger than they are. Does anyone have experience with this sort of thing? Whatever input is appreciated.

Thanks,
Greg

How thick is the aluminum ? And how large are the holes ?

Mooch

Quote Originally Posted past Mooch

How thick is the aluminum ? And how big are the holes ?

Mooch

The aluminum is but the door skin. It's probably sixteen or xviii gauge. The holes on the doors are just from old screw type paring puller repairs and are no more 1/8". The holes in the trunk from the luggage rack are a fleck bigger simply still effectually one/four" at the largest. I'll start with the pocket-sized ones and work upwards. I'm going to effort to fill them this weekend, and so I'll report back.

similar Mike said , some patch pieces ,back information technology up with a piece of flattened copper tubing to suck some heat out , the smaller holes I was thinking of that rod that works with a propane tank , by hazard is this car a MG or a Austin Healy , simply curious thats all ---- FrankT

Quote Originally Posted by shrunken66stroker

The aluminum is just the door pare. It's probably 16 or 18 gauge. The holes on the doors are but from old screw type dent puller repairs and are no more than 1/8". The holes in the trunk from the luggage rack are a fleck bigger but notwithstanding around 1/4" at the largest. I'll outset with the small ones and piece of work up. I'm going to endeavor to fill them this weekend, so I'll report back.

I had some brackets welded on my pontoon boat and so I could move the motor back and it is like shooting fish in a barrel to warp the aluminum And to fire through .

Mooch

Quote Originally Posted by Frank T

like Mike said , some patch pieces ,back it up with a slice of flattened copper tubing to suck some heat out , the smaller holes I was thinking of that rod that works with a propane tank , by chance is this car a MG or a Austin Healy , just curious thats all ---- FrankT

Information technology'due south a 61 MGA roadster. It came from the southwest and is in bang-up shape overall simply in that location have been many easily on information technology over the years. A few quality repairs and a few hatchet jobs.

I dorsum up holes with copper when welding steel but I didn't know it would piece of work the same with aluminum. I'll requite information technology a try. Thanks.