Repairing Holes in Aluminum?

I'm looking for ways on how to repair a hole in my aluminum storm door.

Judy from Traverse


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August 8, 20080 found this helpful

What about getting some aluminum flashing (sold in lowes in different widths by the foot) and maybe silicone sealer it to the door. You could even do a punch tin design on it to make it look pretty. It comes in silver and maybe copper color. I guess you could spray paint it to match too.

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By Tomatohanger (Guest Post)
August 9, 20080 found this helpful

Mend with needle and thread like Grandma used to do when fixing socks. Choose the color closest to your screen color and go.

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By Tomatohanger (Guest Post)
August 9, 20080 found this helpful

Oops -- I thought you were talking about a screen door.

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By Harry (Guest Post)
August 9, 20080 found this helpful

You could buy a small sheet of aluminum at the big box store cut to fit the panel and glue it with an adhesive such as liquid nails. Silicone is an sealer not an adhesive so it would fail in short order.


If you are not particular how the repair looks you could buy a couple of bolts the size of the hole insert into the hole and with washers and nuts screw them together.

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August 10, 20080 found this helpful

Thank you for giving me some ways to fix the door. I appreciate the feedback. Thanks

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August 17, 20080 found this helpful

I see the bottom and I think it is a storm door, right? The kind with the closable plastic glass that slides up over the screen when the wind hits it?
All the above tips are good.
Anyway, if you still buy your coffee (or use any #10 can) in large cans, you can use a crimper to safety seal the edges of the top and bottom round pieces. Seal with liquid nails or an epoxy like E6000 glue. I would take the door off, lay it on a flat surface and do the repairs so you can weigh down the repair for a day or two. Then, seal around the repair with sealent to keep the water out.


If you do the same repair on both the outside and inside, you can literally "sandwich" the holes and drill several small holes between the circles (useing a veggie can size for the little one), and put in small rivots or nuts/bolts. Make sure the bolt is on the outside and seal around them, too. This not only keeps the water out, but keeps you from getting scratched on the end of the bolt that is on the inside.
You might also be able to replace that piece in it's entirety if you find a second hand building supply store or one at a yard sale. You can then paint whatever repair you made to match the door.

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October 4, 20170 found this helpful

I realize this is an ancient thread, but I had exactly the same problem and fixed it with autobody filler. I just followed the directions on the can. It doesn't look great because I used too much and was too impatient, but here's what I did:


-Sanded around the holes
-Cleaned out the mysterious dust-like material, no idea what it is
-Mixed hardener & filler in an old frisbee
-Used a spreader to fill the hole, and here's where I made my mistake. I should have used a little, then sanded it after it dried, then put another coat on, but instead I used way too much and it bulged noticeably higher than the surface of the door
-Sprayed it with autobody primer
-Sprayed with Tremclad metal paint.

It doesn't look great but it does look a lot better, has stopped further damage to the door by stopping water getting into the hole, and next summer when and if I'm motivated to fix it I can do so.

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