Patching/filling holes in Aluminium

[steviec_lj]

Picked up an aluminium load liner for my L200 quite some time back and have managed to get it fitted over the weekend, after quite a bit of faffing around.

Previous owner did a marvellous job of removing the rivets it was held in with, to the point of using an 8mm bit, or in some places a grinder. I’d like to fill some of the surplus holes, and repair some that have been drilled twice.

Ive a blowtorch, propane roofing torch, a MIG and DC TIG.

Other than JB Weld and copious amounts of filing/sanding, what other options are there for this?

For the over sized holes in the bed I thought of using oversize rivets instead of the 4.8mm ones I have in stock.

 

[Ashley Burton]

Large rivets could be a good option, upload us some pictures to show us the current situation

 

[steviec_lj]

Large rivets could be a good option, upload us some pictures to show us the current situation

That would help, yes.

Managed to snap these while waiting for the yard to clear..

 

[Ashley Burton]

Yeah I would go for the river option, They don't look that bad

 

[slim_boy_fat]

@steviec_lj You could always try these, and give us a report on how you fare with them.....

https://www.ebay.co.uk/itm/20PCS-50...a=0&pg=2047675&_trksid=p2047675.c100005.m1851

 

[steviec_lj]

@steviec_lj You could always try these, and give us a report on how you fare with them.....

https://www.ebay.co.uk/itm/20PCS-50cm-1-64ft-2-0mm-Solution-Welding-Flux-Cored-Rods-Aluminum-Wire-Brazing/292505577776?_trkparms=aid=555018&algo=PL.SIM&ao=1&asc=40733&meid=af0243fa2aae47a58905cb3d6ef1cda4&pid=100005&rk=3&rkt=12&mehot=co&sd=183923684121&itm=292505577776&pmt=1&noa=0&pg=2047675&_trksid=p2047675.c100005.m1851

If I can find them in the UK, for delivery before Christmas then in the interests of a review then I shall probably give them a go on some of the thicker pieces.

 

[RonA]

It would be an ideal candidate for Alumiweld rods, problem would be getting enough heat into the parent metal being as Aluminium conducts heat so well.
RonA

 

[julianf]

If they're holes to attach to somthing good (ie right size holes in right places) could you rivet through a washer of some sort (somthing that won't react with the alloy) then through your oversize hole, then into the undamaged hole?

This is assuming a sensible hole behind.


I've got some problems with my landrover. I'm cutting plates out off anodised on the machine, then I'll bolt through them in the same way. I'll probably slap on a load of epoxy in-between also.

 

[Ashley Burton]

I've used those rods & they do work. But with the job shown, I would just rivet & be done with it!

 

[steviec_lj]

Well, 20 rods for less than a couple of pints I’ll give them a bash, worst that can happen is I end up with a puddle of aluminium

Not that I like a job done properly, but I had to do something about the randomly spaced holes that would be visible once the cover is on, with some fancy security bolts too. Need to get some fibre washers or something to go between the two metals to stop corrosion though, I ran out..