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Jim Flanagan
 
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Default Cosmetic Aluminum 'Hole Plugging' Help Needed

Hello..
I have an aluminum radio chassis that I am in the process of
restoring. By restoring, I mean that I have dissassembled the radio to
the bare natural aluminum chassis and am polishing out most of the
scratches, etc. On the back of the chassis, there are two holes approx
#10 screw size that were drilled by a previous owner for no telling
what. Anyway, I need some tips on how to patch these holes in an
attempt to restore the original 'look' of this chassis as best I can.
Here are the options that I have thought of:

Place a screw/nut into the hole and live with it.

Use a press in stud. Do they make aluminum studs?

Have someone attempt to weld up the hole with aluminum and
grind/feather the surrounding aluminum.

I've considered, epoxing a piece of Al disk to the back of hole on the
inside of the chassis. Cutting another disk of Al which would fit the
hole as best as possible and epoxing. Sanding and feathering would then
follow.

What are your opinions as to how and approach this? Since I want the
natural aluminum look, painting is not an option. Thanks for any advice
you would be willing to share.

Jim