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Old 08-21-2023, 08:45 PM
moespeeds moespeeds is offline
Join Date: Apr 2021
Location: Cherry Hill, NJ
Posts: 287

Forget the rivets, use this stuff. 3M Scotch-Weld Epoxy Adhesive DP420, Black, Two-Part Epoxy Structural Adhesive, High Impact and Fatigue Resistant, Maintains Bond Strength, 50 mL (1.69 fl oz) Duo-Pak

If you can find a local water jet guy, have him cut you a plug to match the hole and bond that in place as well. Very little filling will be needed.

See this thread:
Moe Colontonio
Cherry Hill, NJ
RV-8 N495T
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Old 08-21-2023, 10:28 PM
Stewbronco Stewbronco is offline
Join Date: Sep 2019
Location: Langley BC
Posts: 359
Default Best epoxy ever

Developed for FORD GT-40R race car .great strength with FLEXIBILITY
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Old 08-22-2023, 10:48 AM
Ralph Inkster Ralph Inkster is offline
Join Date: Feb 2008
Location: Calgary, Alberta
Posts: 2,143
Default anti collision strobes

Be the first at OSH to have cool strobes mounted flush in your leading edges. Would have to work out a lens & mounting system for them though.

Now retired - my builder assist shop now closed,
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Old 08-22-2023, 02:03 PM
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JonJay JonJay is offline
Join Date: Jan 2007
Location: Battleground
Posts: 4,564

I don’t like hiding repairs on skins. I want to know it’s there down the line.
There are a lot of good suggestions here. First, verify it isn’t a structural concern. If it isn’t, you’re free to do whatever you want, which you are anyway in EAB but….
I would do the backer adhered with Proseal or? And insert a formed aluminum “plug” to match skin thickness. You will still see the plugged hole, but after paint, you will probably be the only one that ever notices. It will simply look like a small round circle in your paint. You could even paint the plug red or something and put a small black dot in the center and folks will wonder what that special sensor is.

If you decide to make it disappear, I have had great luck with Superfil. It’s expensive but doesn’t shrink and sticks very well long term.
Smart People do Stupid things all the time. I know, I've seen me do'em.

RV6 - Builder/Flying
Bucker Jungmann
Fiat G.46 -(restoration in progress, if I have enough life left in me)
RV1 - Proud Pilot.

Last edited by JonJay : 08-22-2023 at 02:06 PM.
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Old 08-22-2023, 06:33 PM
BMallory BMallory is offline
Join Date: Nov 2019
Location: Guyton, Georgia
Posts: 26

Oval doubler on inside reasonably contoured, proseal the edges stick on the inside and pull a vacume through the trimmed hole. Keep the vacume on it. I think it would be benefical to make sure the edges of hole are polished and then plug in manner that allows you to monitor the edges of the hole.
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Old 09-16-2023, 01:23 PM
Kojo Kojo is offline
Join Date: Oct 2020
Location: Englewood Cliffs
Posts: 21

Thanks for all the input. Vans support suggested aluminum doubler and a filler using epoxy. They did not like the idea of rivets in over the leading edge but accepted one in each corner. That is what I did reinforcing interior with some fiberglass layers. Pictures attached for those with interest. Will sand the leading edge and leave the rest to the painting experts who hopefully will agree to do the work once the project is done. Pictures attached.
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