Best way to fill badge holes?
#2240827
01/25/17 02:36 AM
01/25/17 02:36 AM
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Joined: Apr 2006
Posts: 4,220 West Plains, MO
DrCharles
OP
master
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OP
master
Joined: Apr 2006
Posts: 4,220
West Plains, MO
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While sanding off my previous paint mess, I re-discovered that my Dart's front fenders have six badge holes (each). After looking at pics, the original badges appear to be a "Dart" and a big gaudy "Swinger" in script. I may keep the two DARTs but definitely not the "Swinger". So I have a bunch of 1/8" holes to fill. There seem to be several approaches: 1) Countersink the holes and use body filler or epoxy putty; 2) MIG the holes and grind smooth, probably followed by a skim coat of filler; 3) Punch tiny plugs from sheet metal and TIG them in place. I found an article in "Super Chevy" showing it done without even needing filler. I don't have a TIG, and I am not confident in my ability to MIG holes in sheetmetal neatly. I did it on a '65 Ford truck hood a long time ago and it came out OK, but that was heavier-gauge metal and the rest of the truck looked crappy so it wasn't as critical. What do you all recommend? thanks.
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Re: Best way to fill badge holes?
[Re: DrCharles]
#2243640
01/29/17 10:08 PM
01/29/17 10:08 PM
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Joined: Apr 2006
Posts: 4,220 West Plains, MO
DrCharles
OP
master
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OP
master
Joined: Apr 2006
Posts: 4,220
West Plains, MO
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I live in a rural area with the usual subpopulation of thieves and meth-heads, and don't know anyone I would trust to come see my shop... besides I am trying to do everything myself that I can. Today I decided to try soldering (having previously used 80 grit to bare metal). I used a propane torch, brush-on plumbing flux and lead-free solder (for its wider plastic range). I have many years of experience with electronic and copper-tubing soldering. Even so, it took me a few minutes to learn how to control the heat without dropping the puddle... took a few tries but I quickly got the hang of it and filled all eight holes. Then I sanded them all down with 80 grit Roloc discs, went over the entire area with 220 grit on a sanding board, cleaned all the flux residue carefully with water and then grease & wax remover, dried everything and shot a couple of light coats of spray can etching primer. Even with a bright light at an angle, I can't see any trace of the holes
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