Repair hole in aluminum housing

Cacti_Ken · Post by **Cacti_Ken** » Fri Jun 10, 2011 8:59 pm

I have a marker light housing that had a broken screw in it. I managed to get the broken piece out. Now I have to repair the hole. I would like to use the correct lens cover screw again.

Does anyone know if there a product that can be melted/poured into the hole that I drill and tap to support the screw?

Bretto · Post by **Bretto** » Sat Jun 11, 2011 9:03 am

You could always go the JB Weld route. I'm not a huge fan of repairs that way though.

Post by **wesk** » Sat Jun 11, 2011 9:33 am

With an acetylene torch and a cast iron pan you can melt any old aluminum stock and pour it in the hole then just re-drill and tap the hole.

Cacti_Ken · Post by **Cacti_Ken** » Sat Jun 11, 2011 10:46 am

Thanks I'll try that. I tried it with already with some lead free solder, it has tin and something else in it. But still too soft.

Sam-Helm · Post by **Sam-Helm** » Sat Jun 11, 2011 11:40 am

What about the idea of a helicoil? It is not visible, generally, and can be sized dow to the original. Of course, it is not the solution you were asking for, but it would work. . .

53a1 · Post by **53a1** » Sat Jun 11, 2011 6:51 pm

Another option is to drill it out to below round stock size, ream to size, heat housing and drive round stock into the hole coated with thread lock. Grind flush, drill & tap.

RICKG · Post by **RICKG** » Mon Jun 13, 2011 10:23 am

GLAD TO SEE YOU GOT THE BROKEN SCREW OUT, KEN.
I WAS HOPING THAT WOULD WORK OUT FOR YOU..

Cacti_Ken · Post by **Cacti_Ken** » Mon Jun 13, 2011 1:03 pm

Hey Rick, Yeah I finallly got around to doing something with it.

I has become apparent to me that the marker light housings are not the same design. There is a difference from the 1950's and the 60's model.
I noticed that the bulb mounting hardware in the later model is more difficult to manuver into place into its mounting position. I managed to get it in place and set the screws in. I just wasn't aware of the different designs before.

Balvar24 · Post by **Balvar24** » Mon Jun 13, 2011 2:41 pm

Drill and tap hole for next screw size larger. Drill sed bolt out and tap on center to original spec. Remove head. Insert into hole. Use original screw. (Pretty much makes your own helicoil.)