In article et, Jim Flanagan
says...

What are your opinions as to how and approach this? Since I want the
natural aluminum look, painting is not an option.

Aluminum can be soft soldered with the correct solder/flux
combination. I would consider dimpling the hole from the
outside in, and soldering an aluminum disc in place on the
front side, and then feathering it in.

Tig welding the hole shut would produce a nearly undetectable
repair - but of course in both cases the chassis would have
to be nearly completely stripped of components to avoid
heat damage.

Jim

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