Oops...

[AKKen07]

Does anybody know a way to fill a hole in aluminum sheet (About the size of a #40 drill...) for appearance only? Epoxy? For bigger screw-ups Can it be filled with weld to then be redrilled for a rivet? I just can’t bring myself to remake this part ... again. All non-structural boot cowl stuff.

[Mark Goldberg]

You could always put a rivet in the hole. Mark

[robcaldwell]

That's never happened to me. Oh, wait a minute...!

I cut a piece of aluminum slightly larger than the hole. Stuck it to the back side of the hole with DP190 Scotch Weld Epoxy with enough to squeeze through the hole. Once it fully cured (takes about a week) sand it down.

3M DP190 Scotch Weld Epoxy: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

[AKKen07]

I like it! Thank you Rob

[jaredyates]

No welding is allowed on the heat-treated aluminum. Dimple and set a flush rivet like Mark says, and come up with a good story. Like something about how the rivet marks 13.25 inches forward of the datum for easier measurements later.

[AKKen07]

Good to know about the welding. That might work in some spots... not that I have more than one mistake so far... but not the one I’m thinking of. Very entertaining idea for “explaining” the err- um oddity.

[JBC]

Cover a piece of aluminum with electrical tape and place it over the finished side of the hole.(If the whole is near the edge of the boot cowl, clamp it. If in the middle put the aluminum/tape on a bench place the cowl on top and and put wrights around the hole.) From the back side put a dollop of JB weld on the hole. When dry remove the aluminum piece. With a little luck the font side will be as smooth as glass. You can sand the back side down some but the more you can leave the more secure the plug will be,

John Ciolino
Patrol

[AKKen07]

That could work, Thanks!

[zkelley2]

Just put a flush rivet in there.

[AKKen07]

Unfortunately the flush rivet shop end would interfere with another part sitting flush on the back side.

[Chewie]

No welding is allowed on the heat-treated aluminum. Dimple and set a flush rivet like Mark says, and come up with a good story. Like something about how the rivet marks 13.25 inches forward of the datum for easier measurements later.

Exactly! "If you can't fix it, feature it."