How do you fix a oversized hole in sheetmetal ? - JeepForum.com
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Unread 03-08-2014, 05:56 PM   #1
JohnW63
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How do you fix a oversized hole in sheetmetal ?

After years of putting up with a loose soft top attachment groove on top of the windshield, I finally bought the rivet kit that replaces the stripped out holes with stainless rivets and machine screws. All went well but one hole. The last hole on one side, where they mention you need to enlarge a hidden hole below the top hole you just drilled out got slightly ovaled, as I had to angle the bit to open up the inner hole. The two did not line up well, like they did in the driver's side. Now , this one hole is too big for the rivet to hold in.

What are my options ?

If I knew how to weld, I guess I could fill in a bit of the hole and file it out to a proper fit, but I haven't ever welded sheet metal and I have no tools for that. I might be able to take it somewhere to have it done.

What about gluing it in place with something like JB Weld ?

Has anyone run into this issue ?

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Unread 03-08-2014, 06:05 PM   #2
debord97
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If it was mine I would just weld it. I'm sure jb weld would hold it just fine though. I've used jb weld to put all kinds if stuff back together before including a mirror bracket on a 99 firebird.
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Unread 03-08-2014, 06:16 PM   #3
jbolty
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I would cut a piece of tin long enough to cover the hole, glue it in place, put the channel over it then then put a screw or rivet on either side of the damaged hole.
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Unread 03-08-2014, 06:48 PM   #4
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They make different size rivets. If you're using the smaller ones, then you could size up possibly.
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Unread 03-08-2014, 07:33 PM   #5
Mark05059
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there are these things called u-nuts.. they work awesome for that issue.

http://www.itwcip.com/products/u-nuts/
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Unread 03-08-2014, 08:20 PM   #6
JohnW63
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I like the U-nut idea, but there is no edge to slide it on. The hole is on the top corner of the windshield frame.

I suppose the metal over the hole would work. Since the fancy repair kit threaded rivets stick up above the level of the metal, I could use a strip of something the same thickness and attach it over the hole and then use a normal sheet metal screw to hold that one corner down.

If I could weld it and reshape the hole so the spare rivet would fit, I would take that option.

The JB weld option might be a "can't hurt to try " method. I'd have to figure out how to hold it in the hole at the right angle, until it dries. Will that stuff stand up to the tension the top will put on that corner of the channel ?
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Unread 03-08-2014, 10:01 PM   #7
Old4X
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How about a riv-nut and a machine screw?
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Unread 03-08-2014, 10:30 PM   #8
JohnW63
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A rvinut is exactly what the kit came with. If I could find a bigger one, that has the same thread it would work. Not sure where to get them. I've only ever seen them in the repair kit at the Jeep parts web sites.
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Unread 03-08-2014, 10:46 PM   #9
Old4X
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Originally Posted by JohnW63 View Post
A rvinut is exactly what the kit came with. If I could find a bigger one, that has the same thread it would work. Not sure where to get them. I've only ever seen them in the repair kit at the Jeep parts web sites.
\They come in many sizes. The larger ones take bigger screws, but it is simple to mod it to any size screw you want
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Unread 03-08-2014, 11:07 PM   #10
JohnW63
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I think the hole for the ones in the kit is 1/2". I've started looking for some.
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Unread 03-08-2014, 11:07 PM   #11
DirtKar
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There are small washers (backers) that can be used with rivets. Can one be worked into the hole and glued in temporarily then riveted after it sets?
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