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Cosmetic Aluminum 'Hole Plugging' Help Needed
In article ,
says...
On Tue, 20 Jan 2004 23:18:32 GMT, Jim Flanagan wrote:
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
Greetings Jim,
This is a little work but will leave an undetectable repair in bare
aluminum. Go to the hardware store or hobby shop and get a length of
aluminum rod that is close to the same size as the hole. If it doesn't
fit close, that is within about the thickness of a hair or two, then
get the next size up and a drill the same size. Drill out the hole
carefully so it is round. Then hammer lightly on the end of that rod
you bought. Just enough to swell it about 1/64" to 1/32" right at the
end. Hacksaw off this end so it that when pressed into the hole it
protrudes about 1/32". Clean both pieces so there is no oil on either.
Sand lightly the plug before installing. Now, put an anvil of some
sort under the swelled end. A good one would be a flat end punch about
twice the diameter of the hole held in a vice. Use another flat ended
punch placed on the sawed end of the punch and give it a good whack.
This will swell the rivet in the hole and expand the side you are
working on. It is OK to hit it more to get it really tight but don't
over do it. The hammering is going to harden the aluminum and
eventually crack it. After the rivet is tight you can file and sand it
flush. If the aluminum is not anodized it will not show. If you clear
coat it will never show. If left un-coated it will probably eventually
This sounds like something that I can do.. Thanks Eric. I will give it
a try. Take care..
Jim
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