How to Fill a Cast Aluminum Bolt Hole With Melted Aluminum
Many tables and other aluminum objects are designed to be assembled, so they have holes threaded for bolts. If you are using an aluminum object for another purpose, you may find that the bolt holes are unnecessary. You can fill the holes with melted aluminum to create a smoother surface using fairly inexpensive materials. But the process requires high heat and a number of safety precautions to avoid burns and other injuries. When you are finished, you will have smoothed out the surface of your aluminum object. Does this Spark an idea?
Things You'll Need
- Crucible
- Tongs
- Oven gloves or welding gloves
- Gas torch
- Aluminum
- Safety glasses or welding mask
- Iron pan
- Hack saw
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Instructions
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Lay the iron pan on a solid, sturdy surface away from any flammable materials. It is best to work outdoors for better ventilation. Place the crucible on the pan.
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Place the aluminum to be melted inside the crucible. You may need to cut the aluminum into smaller pieces with a hacksaw to fit them into the crucible. Start with a small amount of aluminum. You can add more as the first portion melts.
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Put on the safety glasses and gloves, and have the tongs nearby. Light the gas torch and aim it into the top of the crucible, so you can apply the flame directly to the aluminum. Continue applying heat until the aluminum melts, then add more to the crucible, if necessary, as you continue to apply heat.
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Turn off the torch once the metal is completely melted, and use the tongs to carefully lift the crucible. Pour a small amount of melted aluminum into the hole you wish to fill in your aluminum object. Continue pouring until the hole is entirely filled. Allow several hours for the aluminum to cool.
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Tips & Warnings
Do not touch the crucible or the molten metal, or allow it to come into contact with your skin, as it could cause burns. Wear safety gloves and glasses at all times.
References
- Photo Credit Hemera Technologies/AbleStock.com/Getty Images
