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Need advice on sheet metal patching (tool box)

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Yojinbo

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Feb 14, 2010
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Oklahoma
I have a Lista box (SC) that I got at an auction. Some fine fellow decided to drill a hole in the back rather then consult a locksmith. Actually 3 holes it seems. (I can post pics if needed)

I would like to patch this up so that I can eventually repaint it. I don't care what it looks like inside.

I do not own a torch or a welder and have not done any welding since I left the farm as a boy (oxyacetylene back then).

Fixes I have considered:
* Mounting a D-ring over the hole to cover it. (not classy)
* Patching with one of those metal putty compounds.

I am open to your wisdom on how to proceed on this one. I have never done body work of any kind but I figured this would be a good place to start learning.

Thanks
 
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nolatoolguy

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well if you just wana paint it maybe you can paint it and find a bumpersticker you like and put it over the wholes on the outside i mean other then that without a welder not much you can do


I dont recomend bondo or any of those putties

but thats just me

either way post some pictures when your done and show us how it turned out
 
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Mickey O

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Without a welder I would epoxy a piece of steel on the inside, over the holes and fill them from the outside with body filler, prime and paint.
 
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ZRX61

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I'd cut the hole into a rectangle with rounded corners, shape a patch to fit the hole & then (stitch) weld it into place, grind smooth & paint it.
 
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stricht8

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Welding is of course the only right way to fix it but since that is not an option I would do what Mickey O suggested with the epoxy.
 
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Yojinbo

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Oklahoma
I appreciate everyone's input. This might be one of those 'right' OR 'right now' situations.

Other options that occurred to be after reading your comments:

* I can just grind it smooth and leave it until I have the $$ to get a welder (it is on the want list).

*Or I could talk a buddy into bringing his rig over for a case of root beer (maybe not, have not tried yet).
 
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stricht8

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Even though I support the welding option, there will probably be some heat distortion that will also have to be taken care of if you weld in a patch.
 
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Abodyracer

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Talk to a body shop. They would have all kinds of scrap laying around to patch it up and probably wouldn't cost an arm and a leg.
 
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Brad54

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stricht8 said:
Even though I support the welding option, there will probably be some heat distortion that will also have to be taken care of if you weld in a patch.
Click to expand...

That's what stitch welding is for. No reason you should have heat distortion.

Ideally, as others have said, it should be welded. And since a welder is on your Want List, this could be the perfect time to justify buying a welder!

However, the suggestion about epoxy and a patch behind it is the second-best option. In your shoes, that's what I'd have done. (before I bought a welder two years ago.)

-Brad
 
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Bill Bowman

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Since I'm lazy, and the holes are on the back side, I'd look into making the existing holes a standard larger size (file, die grinder, etc.) and find a metal plug that would snap into the hole (electrical box type). Bill
 
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Yojinbo

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That hole isn't going to plug with anything round.

I found a line on a replacement chassis - but even if I get it I will want to get both looking good.
 
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Az Scooter

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A good welder could fill those holes with wire fairly easily. Grind the back, Grind the front, paint it and be done.
 
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gc11090

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I wouldnt bondo, first grind it flat, tape over the inside with some ducttape, then use fibreglass body filler. Once that dries, sand smooth and bondo over it. Then sand, prime, and paint.
 
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Giraffe

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I'm with Bill, use a hole saw big enough to cover the three holes that are there... looks like 1" might be enough, and then pop in an electrical box hole plug. Depending on the location of the hole, I might even take this one step further (some of you probably won't like this) and drill and plug another hole the same size symetrical with respect to the first and paint over them both. The symetry might make them look like they are supposed to be there. You know, call them "manufacturing holes."
 
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Kevin54

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Giraffe said:
I'm with Bill, use a hole saw big enough to cover the three holes that are there... looks like 1" might be enough, and then pop in an electrical box hole plug. Depending on the location of the hole, I might even take this one step further (some of you probably won't like this) and drill and plug another hole the same size symetrical with respect to the first and paint over them both. The symetry might make them look like they are supposed to be there. You know, call them "manufacturing holes."
Click to expand...

You can't use a hole saw without a guide as it will walk all over the place. Take the hole saw and cut a hole out of a 2x4 or even a 1x4. Then remove the drill bit from the hole saw. Clamp the 2x or 1x over the hole and use this as a guide to go thru the sheetmetal. THEN you can get a metal plug to fit snug as long as the plug and hole are the same size. Weld it then grind it down, or JB weld it, sand it, a little bondo, then paint.

Another thing you could do is use some structural adhesive that they use to glue panels on a car, put a piece of sheetmetal across the inside, glued of course, sand the outside and bondo.
 
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henrys103

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May 29, 2009
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currently exiled in NJ
Yojinbo said:
I have a Lista box (SC) that I got at an auction. Some fine fellow decided to drill a hole in the back rather then consult a locksmith. Actually 3 holes it seems. (I can post pics if needed)

I would like to patch this up so that I can eventually repaint it. I don't care what it looks like inside.

I do not own a torch or a welder and have not done any welding since I left the farm as a boy (oxyacetylene back then).

Fixes I have considered:
* Mounting a D-ring over the hole to cover it. (not classy)
* Patching with one of those metal putty compounds.

I am open to your wisdom on how to proceed on this one. I have never done body work of any kind but I figured this would be a good place to start learning.

Thanks
Click to expand...

Buy some "j-b weld" , a 2 part epoxy that works really well
when it sets, you can sand and paint as you like
 
9

94yj

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Nov 18, 2007
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fort worth texas
ZRX61 said:
I'd cut the hole into a rectangle with rounded corners, shape a patch to fit the hole & then (stitch) weld it into place, grind smooth & paint it.
Click to expand...

that is what i did on my snap on box and you cant tell their was ever a hole there
 
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