Filling in previously drilled hole in panel

[MDG]

What is the best way to do this?  And what material?

[Tomnistuff]

I too need the answer to that question.  My 67 230SL driver's door mirror (black modern plastic) has a 75 mm bolt spacing.  I need to fill at least one hole to space them properly for a goose-neck mirror.  Is the answer "Lead"?

Tom Kizer

[jameshoward]

What is the best way to do this?  And what material?

I would have thought it depends on where the hole is. Some parts are steel. Others are aluminium.

Where is it? A pic would help those that know about bodywork.

[tel76]

You cannot use lead on aluminium, it will not adhere.

[jpinet]

I would epoxy a piece under the hole and fill the hole it with filler, then paint. I know the mirror hole is a small hole, but besides putting a plastic plug in it and leaving it as is, I can't see what else to do. And Tom, I know the top quality of your paint job! I know a guy who can probably match this invisibly with an airbrush.

[andyburns]

I had numerous holes I closed off during the body side of my car.  All of them I welded shut.  With steel its incredibly easy if the hole is less than 5mm in diameter.  Anything over and I welded in a circular cut out.  Its dead easy for anyone with a welder and even minimal skill.  It helps if you have access to both sides of the panel so you can dress back the weld.  A finger sander is a great tool for getting everything back in shape.  Then a very thin smear of body filler and block back.  I had to fill four small holes in the ali door panels as well.  One where the previous owner had drilled holes for speaker wires and the other two were a mirror that had been mounted in the right place.  I didn't feel comfortable welding the ali so I took all of mine down to a professional specialist aliminum welding expert.  It took him about 4 minutes to fill all the holes and he charged me about 10 dollars NZ.  I think this is a pretty good way to fill holes on panel work.  You will be into repainting the panel but I would guess whatever technique you use it would be the same. 

[jpinet]

I had numerous holes I closed off during the body side of my car.  All of them I welded shut.  With steel its incredibly easy if the hole is less than 5mm in diameter.  Anything over and I welded in a circular cut out.  Its dead easy for anyone with a welder and even minimal skill.  It helps if you have access to both sides of the panel so you can dress back the weld.  A finger sander is a great tool for getting everything back in shape.  Then a very thin smear of body filler and block back.  I had to fill four small holes in the ali door panels as well.  One where the previous owner had drilled holes for speaker wires and the other two were a mirror that had been mounted in the right place.  I didn't feel comfortable welding the ali so I took all of mine down to a professional specialist aliminum welding expert.  It took him about 4 minutes to fill all the holes and he charged me about 10 dollars NZ.  I think this is a pretty good way to fill holes on panel work.  You will be into repainting the panel but I would guess whatever technique you use it would be the same. 

I know in Tom's case, his car has an immaculate paint job. Welding would ruin a big part of the paint. I don't know of any other solution besides what I've mentioned earlier that would require minimum touch up. That, or weld that hole shut and get the door repainted completely. But then, will it perfectly match? My guess is that when Tom is finished with his car, it will be close to a 100 points car, if not that.

[jpinet]

I too need the answer to that question.  My 67 230SL driver's door mirror (black modern plastic) has a 75 mm bolt spacing.  I need to fill at least one hole to space them properly for a goose-neck mirror.  Is the answer "Lead"?

Tom Kizer

I issued a couple ideas, but another solution would be to thread the hole and screw from under a correct sized bolt, fixed in place with red Lock Tite, so that it fits almost flush to the top of your door. Then, just a smudge of finishing filler would fill the gaps left around the bolt's diameter. You still would have to have that touched up by a pro with an airbrush, but it's such a small hole, I'm convinced it can be made invisible. Your options are limited I think, because of your new paint job. If it were me, it's one of these things that keep you up at night!

[Tomnistuff]

I obviously had a senior moment.  I'm supposed to be able to remember that my doors are aluminum and that lead does not bond with aluminum.  DUH!!

I like jpinet's idea of bonding a backing plate on the inside and filling the hole with filler, then painting with touch-up paint.  I think I can even handle that myself.

Thanks everyone for the comments.  MDG, do those answers help you too?

Thanks for the backing plate idea, Jocelyn.

Tom Kizer

[stickandrudderman]

FWIW: the only way I would do this is to Ali weld, fill and repaint. Paint match should not be an issue for a professional.

[jpinet]

I obviously had a senior moment.  I'm supposed to be able to remember that my doors are aluminum and that lead does not bond with aluminum.  DUH!!

I like jpinet's idea of bonding a backing plate on the inside and filling the hole with filler, then painting with touch-up paint.  I think I can even handle that myself.

Thanks everyone for the comments.  MDG, do those answers help you too?

Thanks for the backing plate idea, Jocelyn.

Tom Kizer

It see no reason why it would not work. Keep us posted!