Expert: William Forster - 12/18/2006

Question
If filler was to be used, any thoughts on aluminum-filled (Lab-Metal), versus plastic (Bondo) putty as far as durability and restoration value? Also, is there any step-by-step kit available for using lead to repair holes?
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The text above is a follow-up to ...

-----Question-----
How can I fix a round hole ~ nickel-size without using fiberglass or plastic
filler? I have acess to both faces of the metal.
Thanks,
R
-----Answer-----
Hello Ricardo. The only other option is to lead a small patch into it. If it's a newer car, say 1994 on up, the metal is too thin to lead. The heat will distort the hell out of the metal. Lead takes special tools, and a tub of beeswax for the lead paddles. You use acid core solder to tin the surface so the lead will stick, then you paddle lead on over the area. Once the lead has cooled, sand it smooth with 80, then 220. Once you are done sanding, wet sand the area with 400 wet or dry sandpaper. That will neutralize the acid left on the surface from the tinning process. Other than that, the only other method is panel replacement. You can weld a small patch into place, but it will still need some filler work of some sort. You can lead over that, too, if you don't want to use any bondo. No easy fix here, especially under the parameters you have set. Bill

Answer
Aluminum and steel do not mix. They cause each other to corrode. Check ebay for lead kits, or maybe your local Napa store will have some tools publications that can help. Year one has a publication called How to restore your collector car. I highly recommend it. Bill