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Old 11-20-2012, 10:55 AM   #1
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1964 22' Safari
Mason , Michigan
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What do you use to fill screw holes?

Tried to do a search but could not find anything. One of my windows had plastic screwed over it. Now it has a bunch of screw holes around the frame. What can you use to fill these holes in beside using a ton of rivets that really do not look correct.
Any help would be appreciated.
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Old 11-20-2012, 11:03 AM   #2
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Anything will look newer than what is already there, so a perfect match (unless you replace all the exterior panels) is unlikely.

Can a larger frame for the window be made that will cover them? Unfortunately this means that window would match the other windows unless you replaced all the window frames. Or an outer frame that fits under or over the existing frame and extends over the holes could be made for all the windows, perhaps in a contrasting color (Airstream blue?).

The difficulty in solving this usually seems to lead to using rivets.

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Old 11-20-2012, 11:04 AM   #3
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If you have decent (as in very good) aluminum welding skills you could spot fill them. If not about the only thing I could think to do would be to use rivets or screws to fill the holes.

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Old 11-20-2012, 12:59 PM   #4
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Interior or exterior?

Why not just put short self tapping colored headed screws if the hole are inside.

If outside self tapping aluminum.

If the holes are over sized I use small strips of aluminum just smaller than the hole dia. about a 1/4 in. long bent over on itself and hang that in the hole just before installing the screw. That will fill the hole enough to take the screw.
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Old 11-20-2012, 04:04 PM   #5
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Do you plan on any restoration of this new to you 64. If you can get to the back side you can dimple the holes and install flush rivets and the holes will almost disappear. Welding on 2024-T3 is a no no as it is not a weldable alloy of aluminum.
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Old 11-20-2012, 04:18 PM   #6
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It might be helpful to have some pictures - if your screw holes are evenly spaced that is one thing - random is another - too many another yet.

Your challenge may not be so much to work towards a solution that creates a matching and seamless end result but rather a solution that creates contrasting (and complementary) accents in the frame that actually stand out and draw favourable attention to what you've done.

Again - a couple pictures might help.


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