TECH: Filling unwanted trim holes

Ah yes, an oldie but a goodie. We've filled over 130 holes in the body and firewall of my 56 F-100, and nails were a handy tool. I'll second the copper backing for weird shapes.

Throw a round headded nail at a grinder.

 

NTAPHSE wrote:
"I have been using zinc sheetmetal screws without any problems. "

(someday i'll master the quoting process.)

Long term exposure to the zinc welding fumes can damage your lungs. Welding zinc dipped nails or screws is OK with the proper ventilation.

Another tech week idea for my files as I have 30-40 holes to fill on my Volvo.

N B R

 

Great Idea. Thanks

 

Trick I learned from a '60's bodyman - solder 'em shut! Need a big electric soldering iron (its actually copper) or an ordinary soldering copper (heating as needed with o-a torch), tin can material (smooth soup - juice cans or solvent cans, NOT beer or pop cans [aluminum]), 50-50 acid core solder and soldering paste. Steel must clean front and back and inside the hole. Chamfer the front side of the hole. Cut tin patch slightly larger than the hole. Apply soldering paste to tin patch and back of hole (you must have access to backside). Heat backside with hot copper and "tin" the surface around the hole. Then set the tin patch over the hole on the backside, apply heat to the patch until the solder melts, remove the heat. If you are doing this on a vertical surface, you'll have to hold the patch in place with long srewdriver, piece of welding rod, etc. until the solder solidifies. Front side of panel: apply soldering paste and fill the hole with solder ( you will want to hold the patch in place for this operation - it could fall away if you don't). Wash area with baking soda & water mixture followed by a water only rinse. Dry ASAP. Body file the built-up solder, hand sand (do not inhale the solder dust). Best of all, NO warpage or metal distortion, no Bondo. Now you can claim something in common with Bill Hines!

 

Never thought of that. Great idea. Thanks, BOBBY FORD

 

tried the nail thing today,,,,worked like a charm,,

 

hell yeah! glad to hear it!