Sheet Metal Hole Repair

[lmar]

On my daughter's VW Super Beetle Cabriolet a previous owner had filled in the original radio hole with body filler.

They had then randomly drilled a hole on the passenger side just under the windshield (to right of vent area) for an aftermarket radio antenna.

This is what I saw once the filler was ground off.

Using a step drill I open up the hole to get as clean a circle as I can.

I then take an appropriate size coin (In Canada that would be quarters, Loonies ($1.00) and Toonies ($2.00) - and trace it onto a matching metal patch panel.

I then take uni-spotter welding stud and weld it the the correct thickness metal as shown.

Roughly cut out the patches making sure I stay outside the line.

Chuck the stud into a drill and run it against a spinning grinder (securely mounted in a bench vice) and turn the diameter.

Test fit often until you get the fit you desire.

Then, using the welded stud to manipulate the patch until it is level, spot weld it into position.

Remove stud and complete weld. Grind and sand to match existing panel contour.

Do not grind down too much or you will have a flat spot.

Prime and you are done.

This was the same technique I used on the butchered factory antenna hole.

You will note I could not get a clean circular hole without opening up sheet metal (on a curve). Elected to keep it smaller and pre-curved patch to match area in question.

[viiking]

I've done the same but have used donor VW steel.

My only concern with your method is whether there is any problem down the road with the different metal, expansion and contraction and long term stability of adhesion with paints.

From Wikipedia the composition is:

Ring: 99% nickel Centre: 92% copper 6% aluminium 2% nickel
Ring: Nickel-plated steel Centre: Aluminum bronze

Not sure why there are two compositions, maybe different years.
_________________
1968 1500 RHD Lotus White Beetle since birth. In the hospital for major surgery
1966 Lancia Flavia Pininfarina Coupe - in the waiting room
Discharged: 1983 Vanagon, 1974 1800 Microbus,1968 Low Light,1968 Type 3

[lmar]

[Bulli Klinik]

[viiking]

My bad! I clearly didn’t read the story well enough.

I have seen other posters use coins to patch holes and I thought he was doing the same.

Note to self: Please ensure brain is operational before engaging mouth.
_________________
1968 1500 RHD Lotus White Beetle since birth. In the hospital for major surgery
1966 Lancia Flavia Pininfarina Coupe - in the waiting room
Discharged: 1983 Vanagon, 1974 1800 Microbus,1968 Low Light,1968 Type 3

[far rider]

Nice work! Thanks for sharing.
_________________
67 zenith blue sunroof

Contentment; when what you have is what you want.

[lmar]