Patching unused bolt holes in Aluminum

Randy Folsom · May 9, 2024

I am looking for best practices for patching unused bolt holes in the RCR40 Aluminum chassis. These holes are in 3/16” thick plate. I will be drilling new holes in the same area. I am thinking to run a few beads around the edges until the beads fill the hole and are proud of the surface, and then file them flush. I have no experience welding Aluminum, but think MIG will work better as the beads are generally larger. I don’t want to use JB weld or similar because I might powder coat the chassis. Your thoughts please.

Blwngt40 · May 9, 2024

Aluminum Putty 10610.

Like you said welding plugs is best idea as long as you have access a MIG or TIG that has A/C capability. .

Brian Kissel · May 9, 2024

If using a mig on aluminum, a spool gun works the best for us to achieve consistent beads. This helps prevent the aluminum filler wire from stretching.

Regards Brian

Big-Foot · May 9, 2024

You can powder coat JB Weld - I’ve done it….
Another option is to buy aluminum or brass pipe plugs, drill and tap the holes - JBWeld on the threads, grind down the excess..

bryanf · May 9, 2024

I have powder coated both JB Weld and Lab Metal with good results.

With either one you can sand the underside, install a small thin aluminum plate on the underside, and then fill the hole to level.

David Deschamps · May 9, 2024

I've had JB Weld crack and show trough, MIG TIG weld or try aluminum brazing rods they can be used with a propane torch. I have never used them but I have seen some repairs done with them. But do look into them first before you buy or use.

Paul Thon · May 9, 2024

I also have holes to plug. I plan on getting solid aluminum rod close to the hole size. Drill hole out to match rod, cut rod length to hole thickness, chamfer hole and rod install, weld around and sand smooth. I reused the existing roll bar holes and added some more when I changed my rollbar out.

manta22 · May 9, 2024

David Deschamps said:
I've had JB Weld crack and show trough, MIG TIG weld or try aluminum brazing rods they can be used with a propane torch. I have never used them but I have seen some repairs done with them. But do look into them first before you buy or use.View attachment 138784

Avoid those aluminum brazing rods like the plague! They are high zinc content and have low tensile strength and really poor fatigue life. Just find a good TIG weldor and have him fusion weld the plug with an appropriate filler rod alloy.

Jkviper · May 9, 2024

Randy,

I had to plug a bunch of holes in the 3/16” front compartment panels. Welding a tight fitting plug worked well. I have a tig welder. Check out post #437

Joel’s SL-C Build Thread

Joel, I'd leave it where you have it until you get an alignment and check your bump steer #s. The manual will only get you in the ballpark, you'll adjust your spacers when you see what it's doing dynamically.

www.gt40s.com

Randy Folsom · May 9, 2024

All, Thx much for your suggestions and guidance. I think I will invest the money and time to learn how to weld aluminum. Cheers, Randy

David Deschamps · May 9, 2024

Randy Folsom said:
All, Thx much for your suggestions and guidance. I think I will invest the money and time to learn how to weld aluminum. Cheers, Randy

I think that's the best call.

ChrisP · May 10, 2024

Randy Folsom said:
All, Thx much for your suggestions and guidance. I think I will invest the money and time to learn how to weld aluminum. Cheers, Randy

I have TIG and a MIG Spool gun but ended up using the spool gun all the time. I find it easier and quicker. I can weld thin aluminium (1mm) upwards and also braze with it and weld stainless. So easy. I find it really useful and absolutely brilliant!

Randy Folsom · May 10, 2024

ChrisP said:
I have TIG and a MIG Spool gun but ended up using the spool gun all the time. I find it easier and quicker. I can weld thin aluminium (1mm) upwards and also braze with it and weld stainless. So easy. I find it really useful and absolutely brilliant!

Chris, thx for confirming my thoughts regarding investing in a welding rig. Cheers, Randy

manta22 · May 10, 2024

Randy Folsom said:
All, Thx much for your suggestions and guidance. I think I will invest the money and time to learn how to weld aluminum. Cheers, Randy

One other possibility is to insert a drived AN rivet

manta22 · May 10, 2024

My computer crashed before I finished this post.
You can insert a driven AN rivet to plug holes up to about 1/4". Since they are driven into place or squeezed, the rivet metal is forced into the hole radially so it is a very acceptable plug. No welding required with this method.

Randy Folsom · May 10, 2024

manta22 said:
My computer crashed before I finished this post.
You can insert a driven AN rivet to plug holes up to about 1/4". Since they are driven into place or squeezed, the rivet metal is forced into the hole radially so it is a very acceptable plug. No welding required with this method.

If I can’t figure out how to MIG weld aluminum, a driven rivet could be a good option. Thx much for the suggestion.

Mark T · May 10, 2024

I think it’s a great idea. You could even dimple or machine counter sink a flush rivet for a real nice look on one side.

Randy Folsom · May 10, 2024

I priced the cost of rivets, rivet air hammer, and rivet buck. It seems like a bit too much for a solution that would only be occasionally used. The welder cost is higher, but has the potential to be extremely useful.

David Deschamps · May 10, 2024

Randy is it just for appearance reasons that you want to fill the holes.

manta22 · May 10, 2024

Randy Folsom said:
I priced the cost of rivets, rivet air hammer, and rivet buck. It seems like a bit too much for a solution that would only be occasionally used. The welder cost is higher, but has the potential to be extremely useful.

Don't buy one for such a small job- borrow someone's riveter and bucking bar.

Patching unused bolt holes in Aluminum

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