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  #1  
Old January 10th, 2012, 04:01 PM
ajh
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Andrew J. Hutton
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Holes in Bodywork.

So, one of the annoying things about old Land Rovers are all the holes people have drilled in them over time; some you can get away with using filler and other patching but many are in locations likely to crack etc... I have enough MiG/Oxy/Arc experience to fill holes in steel down to about 22ga but I get the impression that aluminium body panels are going to present more of a challenge; I've tried the 'soldier' made for aliminium but never really gotten a good solid repair with it.

So, my question is, on bodywork... any advice? Will a MiG spool gun be able to fill all the 4mm holes without introducing a ton of thermal distortion into the panel?
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  #2  
Old January 10th, 2012, 04:06 PM
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Wolf Fabrication
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My experience welding thin aluminum with a MIG spool gun was not enjoyable, but it got the job done. I did get distortion too. Spool guns are best for thicker material.

If you can, put a small piece of material behind your hole to help fill.

Next time I will just TIG thinner stuff.
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Old January 10th, 2012, 04:13 PM
ajh
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I've been reading up more on lead-loading; but I suspect this is onlly suitable on steel. The amount of heat needed for any torch based repair seems to do more damage than is reasonable. I don't currently have a TiG or that's probably the route I'd take.

On steel using copper sheet behind the hole seems to work OK for the smaller holes.
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  #4  
Old January 10th, 2012, 04:56 PM
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Tin/Aluminum aluminum solders work well for what you are trying to do, but for anything bigger than a 1/16" hole you will need a filler patch of aluminum to back the hole. This is commonly known as Alumaweld at Harbor Freight.

Aluminum welding isn't that hard. You just need to practice. Preferably not on your vehicle first!!
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