How to Repair Small Holes in Aluminum With Vinyl Patches

Although aluminum does not rust, small holes can develop that penetrate thin aluminum and pit thicker aluminum. The majority of aluminum used in boats, recreational vehicles and homes are light gauged and non-structural. In other words, the small holes do not have to be filled to maintain the structural integrity of the part containing the aluminum. Vinyl patches are available that will seal the small holes in the aluminum and remain nearly invisible to the naked eye.

Things You'll Need

  • Rubbing alcohol
  • Distilled water
  • Spray bottle
  • Clean rag
  • Vinyl patches designed for aluminum
  • Scissors
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Instructions

    • 1

      Create a 50/50 solution of rubbing alcohol and distilled water by filling the spray bottle halfway with rubbing alcohol and halfway with distilled water.

    • 2

      Spray the 50/50 mixture onto the surface of the aluminum and scrub the repair area with a clean rag to prep the area for the vinyl patch.

    • 3

      Lay the vinyl patch over the cleaned repair and cut it.

    • 4

      Cut the vinyl patch with the scissors, ensuring that you make it large enough to extend at least one inch beyond each side of the aluminum repair.

    • 5

      Pull 1/2-inch of the protective paper backing from the vinyl patch and press the patch firmly onto the surface of the aluminum repair.

    • 6

      Remove the rest of the paper backing from the vinyl patch and rub it vigorously with the paper backing to adhere the vinyl patch to the surface of the aluminum.

    • 7

      Repeat the process for each vinyl patch you apply to cover the small holes in the aluminum. If multiple patches are required to repair a large section of aluminum, make sure the vinyl patches overlap at least one inch to ensure proper coverage.