How to Do Metal Repair Without Welding

Written by c.l. rease
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Should you need to repair holes and tears in metal and not have the ability to weld, consider another option. Today's epoxies can bond to the metal and once cured, create a permanent repair nearly as strong as the metal to which it is bonded. You cannot use just any epoxy to create a permanent repair on metal. It must be made of particles of the metal that you repairing. For example, if you use a standard epoxy on stainless steel, the epoxy eventually will rust and compromise the repair.

Skill level:

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Things you need

  • Safety glasses
  • Face shield
  • Leather work gloves
  • Wire wheel
  • 4-inch grinder
  • Small block of wood
  • Hammer
  • 200-grit sandpaper
  • Epoxy
  • 4-inch diameter flapper wheel
  • 80-grit sandpaper

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  1. 1

    Don your safety glasses, face shield and leather work gloves.

  2. 2

    Attach the wire wheel to the 4-inch grinder.

  3. 3

    Lower your face shield and thoroughly clean the metal. The metal needs to be shiny and free of corrosion and contaminants that will interfere with the bond between the epoxy and the surface of the metal.

  4. 4

    Place the small block of wood on the outside of the repair and gently tap the inside of the repair with the hammer to close the hole in the metal. You can skip this step if you are repairing a rust hole or the inside of the metal is inaccessible.

  5. 5

    Scuff the area around the repair with the 200-grit sandpaper to give the epoxy a good bonding surface.

  6. 6

    Mix a portion of epoxy, per the application instructions, to cover an area twice the size of the repair you are making in the metal.

  7. 7

    Forcibly press the epoxy into the repair and onto the surface of the metal. Work the epoxy with your fingers until all the air has been removed from the repair area and the epoxy lies flat on the metal's surface.

  8. 8

    Allow the epoxy to cure as specified in instructions.

  9. 9

    Attach the 4-inch diameter flapper wheel to the grinder.

  10. 10

    Grind down the cured epoxy with the flapper wheel to smooth out the epoxy repair.

  11. 11

    Blend the epoxy with the 80-grit sandpaper to create a seamless metal repair.

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