Aluminum body repair

[Keith V]

I need to patch a fairly large hole in the aluminum skin some PO thought was necessary for a porch light.
The new light doesn't cover the hole.

Whats the accepted way to patch the aluminum?
Im thinking JB weld a plate to the inside, then a filler panel in the hole, then body work as usual?

welding is out if the question

Keith
76 Royale
Minnesota

 

[T McManus]

How big an area are you talking about?

 

[Matt Colie]

Keith,
The aluminum skin is bonded to the structural frames as is the assembly of most modern commercial aircraft. You just need to do the correct preparation and find the right glue (adhesive).
As getting to the inside might be a problem with cabinets and trim, you could always put the piece on the outside. If you do, just round the corners and bevel the edges so it look sort of decorative.
Matt

 

[Tom Katzenberger]

Keith,

Make the patch in 2 pieces so that you can slide each half inside the hole then bond the patches to the inside of the motorhome skin.

Hot glue something to the patch so that you can pull pressure against the bonding agent and skin. Rubbing alcohol will release and clean up the hot glue after the bonding agent has cured.

It's ok if you have a small gap between the two patches as that will form a keyway when you apply the filler. 3m Makes great bonding materials, as do many others.

It should turn out well and you will never know it was a hole.

Good luck,
Tom K.

 

[Keith V]

The hole is about 2x3 inches.
There are also screw holes but thats easy

OK off to find a good aluminum adhesive

 

[boybach]

I'd use 5200 or "the right stuff" although 5200 will set up faster. Pop riveting a covering aluminum plate could be used too - could look decorative if done with thought.

Larry

 

[pvfjr]

I saw some awesome and creative solutions out there when I was in the Airstream arena--this topic came up a lot. I didn't find the ones I was thinking of, but there are some great examples here:
https://www.airforums.com/forums/f381/lets-see-your-patches-68104.html

 

[Keith V]

I saw some awesome and creative solutions out there when I was in the Airstream arena--this topic came up a lot. I didn't find the ones I was thinking of, but there are some great examples here:
https://www.airforums.com/forums/f381/lets-see-your-patches-68104.html

Ohh those are Kool, I might have to steal that concept!