How to Repair Holes in Aluminum

Aluminum is a versatile metal, used in construction, transportation and aeroscience. Its characteristics, such as low density and corrosion resistance, make it a popular and useful material. Aluminum is also 100 percent recyclable and easily can be repaired. Whether you want to fix your aluminum siding or mend your aluminum boat, you may want to know how to repair holes in aluminum.

Repairing Small Aluminum Holes

Step 1

Clean the area around the hole in the aluminum with a sponge soaked in warm water mixed with liquid detergent. Rinse thoroughly with water to remove the detergent, dirt and debris. If the hole has parts of the aluminum lifted around it, like flaps, press them down to cover a part of the hole to minimize the damage, If the flaps are severely damaged or uneven, it is better to remove them with tin snips or a similar tool.

Step 2

Mix epoxy according to the instructions on the package. Stir the mixture with a putty knife. Apply the epoxy mixture on the hole, precisely covering it as seamlessly as possible. Leave the epoxy to dry, harden and cure thoroughly for at least one hour.

Step 3

Apply the epoxy mixture on the hole, precisely covering it as seamless as possible. Use the putty knife to spread the epoxy on the aluminum surface. Leave the epoxy to dry, harden and cure thoroughly for at least one hour.

Step 4

Treat the damaged area and the nearby area as well with fine-grit sandpaper.

Repairing Large Aluminum Holes

Step 1

Cut a piece of aluminum about 1 inch bigger than the hole, using tin snips. Place the patch over the hole, holding it with a steel clamp.

Step 2

Weld the patch onto the aluminum with a propane torch. Heat the torch and start welding all around the edges. Continue melting the metal and blending the patch together with the surface of the aluminum until the hole is repaired. Leave the repaired area to cool off thoroughly and to cure.

Step 3

Sand the repaired area with sandpaper, starting with coarse-grit and then moving to fine-grit. Make the patched area blend seamlessly into the aluminum surface as much as you can. Paint the whole surface, using metal paint and a paintbrush, to cover the damage and refresh the look of the aluminum.


Karen Miller

Based in Marlboro, New Jersey, Karen Miller has been writing business- and health-related articles since 1980. Her work has appeared in “Business Week” magazine and “American Health” magazine. Miller holds a Bachelor of Arts in English and theater from Mount Holyoke College.