As you build out your conversion van, you may come across (or cause yourself) a few holes in the metal. They can be on the roof, floor, walls, undercarriage, etc. While they may seem intimidating, and raise major concerns, in reality they aren’t a huge deal and can be rather easily patched - so don’t stress. You won’t want to ignore the holes, because a hole in a metal van can cause various problems, including water and air leaks, which can lead to rust and corrosion. Therefore, it’s important to patch holes in the metal van as soon as they are discovered. There are several options for patching a hole in a metal van, depending on the size and location of the hole, as well as the tools and materials available, along with your general skill level.
Option 1: Welding
Welding is the most common and effective way to patch holes in a metal van. It involves melting metal wire or filler material and applying it to the damaged area, creating a bond that is as strong as the original metal. Welding is the most durable option, and provides the best seal over the long term. However, it’s not the quickest or easiest for DIYers to get started on without previous experience because there are several techniques (ex. MIG vs. TIG) and pieces of equipment needed. We won’t go in depth on welding in this specific article, because most vanlifers will opt for a quicker and easier route. However, if you have a large hole, or major rust in a critical (ex. load-bearing) part of your van, it’ll probably be useful to explore welding. In this case, it may be worth considering hiring a professional to help in-person. Alternatively, if you have experience and the tools, go for it - welding will be your best bet.
Option 2: Bonding
Bonding involves using a specialized adhesive to patch a hole in a metal van. The adhesive is applied to the damaged area, and a patch is placed over the hole. The patch is then held in place using clamps or magnets until the adhesive cures. Bonding is ideal for patching small holes or areas where welding is not possible or practical.
There are various types of adhesives that can be used for bonding, including epoxy and polyurethane. Epoxy is a two-part adhesive that consists of a resin and a hardener. When mixed, they create a strong, durable bond that can withstand high temperatures and exposure to chemicals. Polyurethane adhesives are single-part adhesives that cure when exposed to moisture. They create a flexible, durable bond that can withstand vibration and impact.
Epoxy
Epoxy bonding is one of the most common and practical routes for DIY vanlifers to fix metal holes, because it can be done with minimal tools, experience and time. There are even epoxy-based metal patch kits at large hardware stores that have basically everything you need to get the job done. Apart from traditional welding, epoxy bonding is one of the most effective and durable options for a long-term seal that vanlifers can complete. Fixing a hole in metal with epoxy is a simple process that involves the following steps:
Clean the area around the hole: Before applying the epoxy, it is important to clean the area around the hole thoroughly. Use a wire brush, coarse sandpaper, or other abrasive tools to remove any rust, debris, or loose paint from the area. This will ensure that the epoxy can bond properly to the metal surface. If there is a large amount of rust, you should cut it out using a hacksaw, grinder or shear. If you have a large amount of rust, you may want to look into using rust converter solution.
Mix the epoxy: Most epoxy compounds consist of two parts that need to be mixed together in equal amounts. Follow the manufacturer's instructions to mix the epoxy properly.
Coat the edges of the hole: Apply the mixed epoxy to the edges of the hole and the surrounding area using a putty knife or similar tool. Be sure to spread the epoxy evenly.
Cut a fiberglass screening: Apply it on the backside of the metal - typically you’ll want to cut it an inch or so larger than the diameter of your hole. Coat the edges again with epoxy to secure. If your hole is small, this step may not be necessary. Depending on the size of your hole (if it’s incredibly small) you can alternatively fill with a bolt or screw.
Cover with epoxy: On the front side, cover the screening fully and fill the hole completely. For larger holes, apply the epoxy in layers, allowing each layer to dry before applying the next one. Let the epoxy overlap beyond the hole, and build it up slightly higher than the surface of the metal. Smooth the epoxy so it’s relatively flat, but don’t worry too much - you’ll end up sanding down.
Allow the epoxy to dry: Follow the manufacturer's instructions for drying time, which can vary depending on the type of epoxy used. Once the epoxy is dry, it should be hard and firm to the touch.
Sand the epoxy: Once the epoxy is dry, use sandpaper to smooth the surface and remove any rough edges. This will help create a seamless repair that blends in with the surrounding metal surface.
Paint the repaired area: If desired, you can paint the repaired area to match the surrounding metal surface. Be sure to use a high-quality paint that is designed for use on metal surfaces; vanlifers often use or complement with a rust-aware solution like rustoleum.
By following these steps, you can effectively patch a hole in metal with epoxy. However, it is important to note that epoxy may not be suitable for all types of metal or for larger or more complex repairs.
Sheet metal can also be used to patch a hole in a metal van by cutting a piece of metal to fit the damaged area and bonding it into place (it’s more common to weld). Sheet metal is available in various gauges and can be cut to fit any size or shape. Sheet metal is ideal for patching small holes or areas where welding is not possible or practical.
To use sheet metal for patching, the damaged area is cut out using a cutting wheel or saw. A piece of sheet metal is then cut to fit the hole, and the edges are shaped to match the contours of the van. The sheet metal is then welded or bonded into place using an appropriate method.
Option 3: Tapes and instant patches
Specialty tapes such as metal repair tapes and foil tapes are designed to provide temporary solutions for small and simple repairs. While they can be used to patch small holes in a metal van, they are not a permanent solution and are not recommended for larger or more complex repairs. Vanlifers will use tapes when on a very low budget, or if looking for a quick, easy and temporary fix. Some people turn to tapes like eternabond and similar options, but please be aware that these will never be as permanent, sealed or durable as bonded or welded solutions. Tapes can also be used in combination with bonding adhesive like epoxy or liquid weld for a more effective solution.
Metal repair tapes are made of a flexible and durable material that can conform to the shape of the hole and provide a temporary seal. However, they are not designed to withstand the stresses and pressures of daily use and can degrade over time, leading to further damage to the metal. Foil tapes are made of a thin layer of metal foil and a strong adhesive that can bond to the metal surface. They are ideal for sealing small cracks and gaps in metal, but they are not suitable for larger or more complex repairs.
Instant patches include self-adhesive patches (ex. UV repair patch) that can be immediately applied to the hole and create a seal. Spray or silicone sealants can also be used to patch instantly. There are several ‘instant’ repair patch kits sold at hardware stores and online that can give you a quick and easy fix - however, these are not great permanent solutions.
In general, while specialty tapes and instant patches may provide a temporary fix for small holes in a metal van, it is always recommended to use more permanent solutions such as welding or bonding.
Where can I find first-hand answers and experiences about patching a hole in a metal van build?
Reddit is a great start: