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Filling small holes in panel?



 
 
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  #11  
Old December 8th 19, 05:38 AM posted to rec.aviation.soaring
soaringjac
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Default Filling small holes in panel?

On Saturday, December 7, 2019 at 6:52:38 PM UTC-8, weemacgregor wrote:
On Saturday, 7 December 2019 18:12:08 UTC-5, soaringjac wrote:
Any recommendations on what to use to fill small holes in an aluminum panel?


How small?


about 3/8th
  #12  
Old December 8th 19, 06:10 AM posted to rec.aviation.soaring
Cookie
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Default Filling small holes in panel?

aluminum brazing rod and propane torch. Did an old Grob Panel with many holes. Learning curve required. Can warp if not careful...may have to flatten out after.

When finished don't paint....grind and sand repair areas to flat....

Then use 3m 1080 vinyl wrap..."anthracite" color carbon fiber...looks great, easy.


Cookie
  #13  
Old December 8th 19, 08:13 AM posted to rec.aviation.soaring
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Default Filling small holes in panel?

On Saturday, December 7, 2019 at 9:10:24 PM UTC-8, Cookie wrote:

Then use 3m 1080 vinyl wrap..."anthracite" color carbon fiber...looks great, easy.


Would 1080 vinyl be a good material to cover crazed gelcoat?
  #14  
Old December 8th 19, 02:40 PM posted to rec.aviation.soaring
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Default Filling small holes in panel?

On Saturday, December 7, 2019 at 6:12:08 PM UTC-5, soaringjac wrote:
Any recommendations on what to use to fill small holes in an aluminum panel?


Very small(screw) holes can be filled by counter sinking and putting a flat head screw in, followed by a bit of filler.
Larger(switch size) holes, assuming no interference with something on the back face, can be covered from the back by a small piece of aluminum, bonded with epoxy, followed by filling he hole with body filler.
Unsupported body filler will fail in a short time.
Good Luck
UH
  #15  
Old December 8th 19, 02:41 PM posted to rec.aviation.soaring
carbonprop[_2_]
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Default Filling small holes in panel?

On Saturday, December 7, 2019 at 4:12:08 PM UTC-7, soaringjac wrote:
Any recommendations on what to use to fill small holes in an aluminum panel?


https://www.amazon.com/s?k=black+hol...sb_ss_i_3_ 16
  #16  
Old December 8th 19, 09:57 PM posted to rec.aviation.soaring
Cookie
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Default Filling small holes in panel?

I just got word that "vinyl wrapping" has been approved in Europe for many makes and models of gliders.

To cover crazed gel coat...IMHO...not a good choice.

Two reasons. 1080 has an outdoor exposure life of maybe 4 years....so maybe if a glider is kept inside most of the time it would be OK.

Also vinyl wrap gets almost impossible to remove if it is left on for 4 years...
In most automotive used it is sort of semi permanent, removed and replaces periodically.

As for covering the crazing...it won't really...the vinyl take on the shape of the under surface so I am afraid that the crazing will show through somewhat. Also the crazing may continue to get worse under the wrap.

I just did a wrap on my car roof, to cover up blistering and peeling clear coat...BUT I had to wet sand 400 grit and remove all traces of the clear coat before applying the wrap.

Wrapping is not all the inexpensive.

Cookie


On Sunday, December 8, 2019 at 2:13:03 AM UTC-5, wrote:
On Saturday, December 7, 2019 at 9:10:24 PM UTC-8, Cookie wrote:

Then use 3m 1080 vinyl wrap..."anthracite" color carbon fiber...looks great, easy.


Would 1080 vinyl be a good material to cover crazed gelcoat?


  #17  
Old December 8th 19, 10:00 PM posted to rec.aviation.soaring
Cookie
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Default Filling small holes in panel?

On Sunday, December 8, 2019 at 8:40:36 AM UTC-5, wrote:
On Saturday, December 7, 2019 at 6:12:08 PM UTC-5, soaringjac wrote:



Using the aluminum brazing method, the panel comes out flat on both sides...so new holes can be put where you need them. Patches on the backside and thru screws, and pockets of Bondo, may prove problematic if they interfere with the new installation.

Cookie
Any recommendations on what to use to fill small holes in an aluminum panel?


Very small(screw) holes can be filled by counter sinking and putting a flat head screw in, followed by a bit of filler.
Larger(switch size) holes, assuming no interference with something on the back face, can be covered from the back by a small piece of aluminum, bonded with epoxy, followed by filling he hole with body filler.
Unsupported body filler will fail in a short time.
Good Luck
UH


  #18  
Old December 9th 19, 01:06 AM posted to rec.aviation.soaring
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Default Filling small holes in panel?

On Sunday, December 8, 2019 at 4:00:40 PM UTC-5, Cookie wrote:
On Sunday, December 8, 2019 at 8:40:36 AM UTC-5, wrote:
On Saturday, December 7, 2019 at 6:12:08 PM UTC-5, soaringjac wrote:



Using the aluminum brazing method, the panel comes out flat on both sides...so new holes can be put where you need them. Patches on the backside and thru screws, and pockets of Bondo, may prove problematic if they interfere with the new installation.

Cookie
Any recommendations on what to use to fill small holes in an aluminum panel?


Very small(screw) holes can be filled by counter sinking and putting a flat head screw in, followed by a bit of filler.
Larger(switch size) holes, assuming no interference with something on the back face, can be covered from the back by a small piece of aluminum, bonded with epoxy, followed by filling he hole with body filler.
Unsupported body filler will fail in a short time.
Good Luck
UH


  #19  
Old December 9th 19, 01:51 AM posted to rec.aviation.soaring
Gary Wayland
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Default Filling small holes in panel?

On Saturday, December 7, 2019 at 6:12:08 PM UTC-5, soaringjac wrote:
Any recommendations on what to use to fill small holes in an aluminum panel?


Assuming 80 MM is a BIG hole...

How about another cool wiz-bang super-secret vario that just came on the market! At 57 MM for your convenience! Merry Christmas

On switch size hole... Do not plug! Part of the feng shui of a used or antique soaring plane...

(the other guys on this thread had some great ideas to plug) pouring epoxy in the hole that has tape on the back or Tig before you fill the hole. Countersinking a bit to spread the hole bigger may give you more surface. The biggest problem; the aluminum is thin to get a lot of surfaces to adhere to.... Bondo will fail in a short time because of the small amount of surface area...
  #20  
Old December 9th 19, 03:42 PM posted to rec.aviation.soaring
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Default Filling small holes in panel?

I have a good friend that has a bullet hole through his glass panel. We fixed everything else on the ship but the panel. That hole is part of the history of the ship.
UH


On occasion, I have considered punching a few .45 holes through my vario and altimeter for giving me unwanted information.
 




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