Capping off holes

[Welderpaul]

Got some 3mm wall box section posts that we ended up having to drill 25mm holes in the faces of to hide bolt heads/washers for fixing purposes.
To plug the hole we would normally knock a 25mm round plug in, but this would sit proud by 3mm or so.
Can anyone think of a better solution of making the hole disappear?
It's also the sort of place that things like plugs in holes etc get tampered with - better to be something more resiliant.

Posts are galv and powdercoated so can't weld em

 

[the snooper]

hmm a hard one without welding

 

[bigbadbugga]

Could you rivet a steel disc over the hole with a strip of steel inside the hole to bridge it?

sort of like this..

sorry for the bad pic

 

[john224]

hole

Make a plug and glue up and knock the plug in then clean up and touch up plug with paint??

 

[spaffmonkey]

Milliput and paint

 

[chunkolini]

Go round the holes with a die grinder, leavng a nice sharp burr.
One tinkerer with a lacerated finger tip will put a stop to it.

Chunko'.

 

[astro_al]

You could use metal filler - its not tamper=proof, but if you do a good enough job of it, no-one will be able to tell its there, so they won't try.

I used it once on a galved piece (to cover required vent hole), sanded it down flush and sprayed zinc cold galv stuff over the top. Absolutely undetectable.

Cheers, Al.

 

[Welderpaul]

You could use metal filler - its not tamper=proof, but if you do a good enough job of it, no-one will be able to tell its there, so they won't try.

I used it once on a galved piece (to cover required vent hole), sanded it down flush and sprayed zinc cold galv stuff over the top. Absolutely undetectable.

Cheers, Al.

Aye, but its powdercoated as well though

 

[brightspark]

go down motor factors and get some core plugs tap.:: em in

 

[Bsmith]

go down motor factors and get some core plugs tap.:: em in

I was thinking the same only I call them frost plugs, same thing

 

[Hitch]

How big is the box.... if its only small, you could perhaps use shoulder screws, so the head is flush , just a mm or so gap round it....

 

[Mikey D]

could you tap the holes and use these , put some high strengh stud lock on the threads and they arent coming out !
http://www.tlc-direct.co.uk/Products/CO25SP.html

cheers mike

 

[runnach]

Expanding foam, leave till solid of course, then smooth off, finished with a quick lick of galvafroid paint?

 

[Welderpaul]

Bought some plakky plugs. Gonna spray em.

Hate bodging.

 

[chap]

Turn some ali plugs; 0.5/1mm high lip?