filling holes in sheet metal?

[Mike D]

Any tips or ideas on how to fill holes in sheet metal? Like the holes left behind after moving an antenna or pitot tube? This is a finished and plane.

Fiberglass? Sheet metal patch riveted on? Or maybe some sheet metal and proseal?

For now it just has a patch of aluminum tape. Works but not pretty.

[LifeofReiley]

if you're dealing with round holes, the flush pop in plugs fit tight and can be epoxied in place.

[RV7Guy]

As Reilly mentioned, you can get one of those pop in caps. Drill as appropriate. I recommend Click Bond as the adhesive. It won't be going anywhere.

THEN, if anybody asks just tell them about the mandatory service bulletin requiring the mod

[Walt]

Stainless screw/nut.

[aerhed]

If you have an odd hole like a streamlined pitot hole, you could flush patch it. Use a piece of Al the same thickness as the skin and cut/file a plug that fits the hole exactly. Rivet this to a larger patch that will fit inside. You could probably get 4 rivets in a pitot shaped hole patch. Then you can pick up the existing rivet holes in the skin and add as many more as you need to lock your patch in flush. Afterwards it can be sanded and have the seam filled to be invisible.

[comfortcat]

*sigh* I have a couple of these and my plane is not yet flying!

go to

http://www.mcmaster.com

and do a search on

sheet metal plug

metal one are at the bottom.

cc

[bret]

Originally Posted by comfortcat

*sigh* I have a couple of these and my plane is not yet flying!

go to

http://www.mcmaster.com

and do a search on

sheet metal plug

metal one are at the bottom.

cc

Me too, just added two extra holes for no apparent reason, ok stupidly was the reason..

[JonJay]

Originally Posted by aerhed

If you have an odd hole like a streamlined pitot hole, you could flush patch it. Use a piece of Al the same thickness as the skin and cut/file a plug that fits the hole exactly. Rivet this to a larger patch that will fit inside. You could probably get 4 rivets in a pitot shaped hole patch. Then you can pick up the existing rivet holes in the skin and add as many more as you need to lock your patch in flush. Afterwards it can be sanded and have the seam filled to be invisible.

When properly done as described it looks professional and appropriate, even when the joint is not filled. A patch is a story and adds to the character of the aircraft. Sadly I have none on my machine, yet.....

[CharlieWaffles]

Originally Posted by comfortcat

*sigh* I have a couple of these and my plane is not yet flying!

go to

http://www.mcmaster.com

and do a search on

sheet metal plug

metal one are at the bottom.

cc

Home/Aviation Depot carries a number of these in metal and various sizes as well for local sourcing.

[bruceh]

Bond a piece of aluminum on the inside, then fill the hole on the outside with some JB weld. Put some packing tape over it (not the sticky side) to let it dry smooth. Then sand it flush and paint.