How to fill holes in metal without welding

In fabrication, one of the very versatile materials is sheet metal.  This metal is used in multiple industries and applications. In manufacturing, sheet metal is widely used due to sheet metal flexibility.  The sheet metal could be very prone to destroy in applications of high wear & tear. It damages or destroys due to multiple reasons such as due to weak spots, low maintenance, and accidents over numerous years it could cause small holes to create in that sheet metal. Holes are caused in the sheet metal, especially due to rust. Many reasons can cause massive damage in the metal sheet; along with this, you could have many options for repairing these holes effectively and quickly patch up the material you have.

How to fill holes in metal without welding A picture of Hole

The first choice of somebody is to fill the holes in sheet metal by using welding.  If there is a hole in a stainless tank or metal door and you want to repair it, then the optimal solution for repairing them is welding because it provides the most permanent and strongest choice.  During welding, an individual can apply an advanced and new metal layer to existing metal to maximize its durability, making it stronger and thicker than its original. This process is carried out effectively.   There are specific ways to do repairing by using the welding technique relied on the kind of its application and metal types, for example, fixing different holes in the body of the car. Expert and experienced welders would know more effectively regarding other techniques used for welding. These techniques are applied to make the process of repairing stronger and more effective to avoid future cracking.  Whenever hiring an expert welder to repair the metal holes, make sure regarding the technique that the welder uses, like TIG or MIG arcs.

But, How to fill holes in metal without welding?

Tape or Epoxy

Tape and epoxy are two standard methods in which no welding option is available.  When repairing small holes instead of significant holes, then approaches of do-it-yourself are more effective. Specialty tape & epoxy products or items are designed for the purpose to patch metal and steel.  When individuals use epoxy and plug a small hole, it could sometimes be the permanent solution, relying on the damage extent & patch job quality. It would help if you were ensured that to apply a primer coat to the patched area.  Then seal the entire epoxy & avoid the hole form recreating. Aluminum tape or duct tape is a quick fix, simple specifically for auto damage of the body. The tape is solely considered a very temporary solution to fix the holes in any metal type or the car body.

Small Holes can be Fixed by Using a Repair Patches of UV

For a more permanent and durable way for repairing holes in the various metal, the sheet can be done without welding by using a repair patch, which is named UV. For small rust or holes damage, these patches are considered as instant fixes. It helps you to run and take back up quickly.

The patch is applied to a rusted area or hole & for UV rays in a significant way. It is waiting, which comes from sunlight, which activates the entire patch, significantly less time hardening after the initial exposure. If someone is working in the area from where there is no possibility of sunlight, then repair patches of UV could be cured and activated using a lamp from where UV light exerted. Repair patches of UV are very flexible, and it has cloth-like stuff that could conform toward any surface for perfect and practical fit. With metal surface, permanent bonds are created by repair patches of UV as industrial adhesive, providing hole repair without welding, and it is long-lasting. These patches have different advantages, such as these patches are waterproof, meaning that individuals won’t need to worry regarding additional rust or leaks.   Repair patches of metal are very resistant to oil or corrosion. It does not have a significant exposure regarding UV light. If the repair patch of UV is applied, then it’s a speedy procedure; it takes significantly less time to apply paint and sand from beginning to end.

This article will discuss that if someone requires to repair the tears and holes in metal without welding, then there are multiple options to do so.

Today’s explosives could make a strong bond to metal &, once cured, nearly make permanent repair significantly stronger like metal with which epoxies are bonded. On metal for the creation of permanent repair, any epoxy is not only to use. It should be created by using metal particles that the individual is repairing. If on steel, which is stainless, eventually, the epoxy will compromise and rust the repair.

Step 1

Use different things for safety, such as work gloves made of leather, face shield, and safety glasses.

Step 2

To the grinder, which is around 4 inches, connect the entire wire wheel.

Step 3

Metal is cleaned thoroughly by lowering the face-shield. The metal must be gleaming & corrosion-free and contaminants free that would interfere with strong bonds among metal surface and epoxy.

Step 4

On the repair outside, place the small wood block & tap the repair inside gently by using a hammer. It is used to close a hole that is present in the metal. This step could be skipped if the individual repairs metal inside or hole, which is not accessible.

Step 5

Using the sandpaper of around 200-grit, scuff the entire area, which is present nearly to repair. The sandpaper provides the epoxy with a good surface for bonding.

Step 6

According to instructions of application, some epoxy portion is mixed to go through the area twice a compare to the repair size that an individual is creating in the metal.

Step 7

Into the process of repairing, epoxy is pressed forcibly & onto the metal surface. Using your fingers, epoxy is worked until the entire air from the area of repair has been discarded & epoxy presents flat on the metal’s surface.

Step 8

Permit the epoxy according to instructions that are specified for a cure.

Step 9

To grinder, connect the flapper of around 4-inch diameter.

Step 10

By using the flapper wheel, cured epoxy is grinded to smooth the entire epoxy repair process. Epoxy is blended by using around 80 grit sandpaper to make an effective metal repair.

There are different stages involved in repairing the hole without using the welding process.

Hole is Prepared

Coarse sandpaper is used to remove rust, dirt, oil, and paint from the metal surrounding in a significantly less wide border of one inch around the captured hole on metal both sides; use the applicator or putty knife, which is supplied along with the entire kit for the coating purpose by using epoxy filler. Then the putty knife is used to be pressed into epoxy. The fiberglass screening piece edges cut around 1-inch larger as compared to the hole. Let’s cure the epoxy, following the instructions of makers.

Filling the Entire Hole

From front side working & using different equipment such as a putty knife, stiff cardboard piece, or kit applicator, epoxy covers the entire screening. Epoxy is applied until the real hole is repaired or filled. Epoxy is built above the metal surface & hole edges are slightly overlapped.  Permit the epoxy to be the cure.

Sanding the Entire Patch

Sandpaper, which is made of silicon carbide, is used to decrease the dry epoxy of the surrounding metal level; a power sander would speed the entire job. After this, use sandpaper, which is around 80-grit, and it is followed by 300-grit or 200-grit to create the glass-smooth patch.

Coating the Entire Patch

To discard grit and dust, the patch is wiped by using the cloth, which is soft and soaked in the rubbing alcohol. By using primer, spray the entire patch. Can hold around 6-inches from the metal surface & slowly moving it in a straight line from the side, not pushing it in an arc.


The conclusion drawn from the above discussion is that metal can be repaired without welding. There are many ways to do so. Many reasons can cause massive damage in the metal sheet, along with this, you could have a lot of options for repairing these holes effectively and quickly patch up the material you have. Small holes can be fixed by using a repair patch of UV.