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How to patch a hole

Flyinfool

By Flyinfool
in Watering Hole

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Flyinfool

Flyinfool

Posted
Posted

On the new to me truck that I just bought I have found that there is about a one inch hole punched in the roof for probably an antenna. I did not notice it till now.

 

What is the best way to permanently patch that hole.

Cosmetics do not have to be perfect since only someone over 7 foot tall will ever see it unless they make an effort to get up above the truck. For now it is covered with gorilla tape.

 

I thought about just using a plug made for electrical panels and load it up with caulk, install it in the hole, give it a squirt of red paint and call it close enough. But I think I want it a little nicer than that.

 

Plan 2 was to cut a plug to fit the hole and try to weld it in without starting the truck on fire, then add filler and paint. but this has the potential of making a mess. I am not real good at body work.

 

Anyone have any other ideas, short of just taking it into a body shop?

jakester

jakester

Posted
Posted

I have seen the black rubber/plastic plug installed with a sealer. It looked professional, not bad, and semi perminant. I would not try to color match. As you said .... It is not visable unless you were above the pickup. Should be able to find this type of plug at any two way radio shop.

Bill

Peder_y2k

Peder_y2k

Posted
Posted

You might check out a hardware store (like ACE) that has a screw assortment section. There are black plastic hole pulgs in several sizes that simply snap in place, provided the hole is perfectly round. I'd apply some clear silicone to the plug contact area and install, then clean wipe the excess. Solvent (acetone) clean it if you intend to paint it.

I had a Forest Service surplus Bronco with e-lights roof holes that were plugged this way, and it seems rather permanent. Anyways..... the plug won't rust.:080402gudl_prv:

-Pete, in Tacoma WA USA

'83,88

djh3

djh3

Posted
Posted

The plastic "body plugs" are the way to go. A little silicone sealer and pop in. Same kind they use to plug holes in firewall of cars of unused wires etc. Might try auto store on "help" rack.

oldfaithful

oldfaithful

Posted
Posted

Your best fix is to cut a piece of steel bigger than your hole. Place it on the inside and weld in place. I have a 110V Lincoln mig welder that can run as a mig (with sheild gas) or with flux wire, and recently did this exact patch with 0.030 flux core wire. Then fill with bondo, sand to preference and prime/paint as you like.

 

If you need an easier (aka no welding) patch method, then make your steel piece with several small holes drilled in it. You can add a few small holes to the roof too if you like. Then affix the patch in place, from the inside, with JB Weld. Now just spread your bondo across the entire area and allow the filler to ooze thru the holes. It may take several applicaitons, usually slower & thinner applications will work best. Just be sure when sanding that you don't get all the way down to the steel. Leave a layer of filler to hold the patch in place. There is even some fiberglass mesh you can apply to the inside to give the filler something to form onto on the back side. Bondo is suprisingly strong filler, and will do fine, so long as its not a highly stressed area on the body. It's not fancy, and may crack in a couple years, but you were asking for alternatives...

wes0778

wes0778

Posted
Posted

Cut an oval piece of galvanized sheet metal. The small diameter is just small enough to go in the hole in the roof. The long diameter will be larger than the hole in the roof. Drill a small hole in the middle of the metal oval and put a stiff wire through the hole and bend it over so the metal oval is hooked to it. Now feed the oval through the hole in the roof and hold it up against the underside of the hole in the roof, with the stiff wire. From here, you can use solder to attach the oval to the underside of the roof and also fill in the hole. I guess you could also use some of today's high strength adhesive instead of solder. Level the hole with body filler, sand prime and paint.

muffinman

muffinman

Posted
Posted

Jeff go find an A&P mechanic and have him do a standard sheet metal repair to it with solid rivets it will never be an issue after that. Or you could drive it down here to NC and I can do it for you.

 

 

 

Jeff

djh3

djh3

Posted
Posted

Find a local shop that installs bussiness radios. They should have a blank cover to go in it. I'm pretty sure if I'm welding a hole up in the roof I maight as well figure in a 1/2 paint job on the truck. If its a beater like my 96 I'd maybe try the fiberglass and a rattle can of color match stuff. I think I'd go the plastic plug route first though. Less muss n fuss

Flyinfool

Flyinfool

Posted
  • Author
Posted

Some good ideas here.

 

I went out and measured the hole. It is .760 dia, just a hair over 3/4 inch or 19.3mm

 

I'll do a reconosince run at the hardware store tonight to see what I can come up with.

 

I am thinking of this type of plug.

http://images1.mcmaster.com/Contents/gfx/large/9563k68p1l.png?ver=8850358

 

Or this type plug.

http://images1.mcmaster.com/Contents/gfx/large/9750kp1l.png?ver=7918388

 

I can paint it to match and then just pop it in with the backside loaded with clear silicone and wipe off the ooze that comes out around the edges. Even if I don't paint it, no one will ever see it. both plugs are cheap enough even from McMaster, I'll just have 99 spares for my $3.50. :whistling:

 

As I work on stuff I am finding more and more holes from things that were mounted and removed.

playboy

playboy

Posted
Posted
Find a local shop that installs bussiness radios. They should have a blank cover to go in it. I'm pretty sure if I'm welding a hole up in the roof I maight as well figure in a 1/2 paint job on the truck. If its a beater like my 96 I'd maybe try the fiberglass and a rattle can of color match stuff. I think I'd go the plastic plug route first though. Less muss n fuss

 

 

:sign yeah that: Like you said unless your 7' tall you will never see it. I have used these after removing Fire Dept radios without any sealant and had no issues. But a little silicone wouldn't hurt. After a week you will forget all about it until you get in the bed to wash it out.

bkuhr

bkuhr

Posted
Posted

http://images1.mcmaster.com/Contents/gfx/large/7845kp1l.png?ver=3940239

This type of conduit plug at mcmaster would work well if you can access the inside to tighten wingnut.

dacheedah

dacheedah

Posted
Posted
Some good ideas here.

 

I went out and measured the hole. It is .760 dia, just a hair over 3/4 inch or 19.3mm

 

I'll do a reconosince run at the hardware store tonight to see what I can come up with.

 

I am thinking of this type of plug.

http://images1.mcmaster.com/Contents/gfx/large/9563k68p1l.png?ver=8850358

 

Or this type plug.

http://images1.mcmaster.com/Contents/gfx/large/9750kp1l.png?ver=7918388

 

I can paint it to match and then just pop it in with the backside loaded with clear silicone and wipe off the ooze that comes out around the edges. Even if I don't paint it, no one will ever see it. both plugs are cheap enough even from McMaster, I'll just have 99 spares for my $3.50. :whistling:

 

As I work on stuff I am finding more and more holes from things that were mounted and removed.

 

Top plug with a bead of silicone is what they put in old squad cars, or just stick an antenna back in it.

juggler

juggler

Posted
Posted

You could use JB weld, sand it and paint it.

 

A plug like you mentioned would work.

 

OR install your own antenna - there has to be a toy you need for the truck? right?

Sylvester

Sylvester

Posted
Posted

Just use the rubber plug you pictured with a little silicone. My father was a heavy highway contractor with 2 way radios in most trucks. When they were ready to be replaced the rubber plug was used and no body complained.

 

:farmer:

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