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Thread: Filling in drill Holes in panniers

  1. #1
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    Filling in drill Holes in panniers

    Just converted my aluminium panniers to fit on Touratech rails, having been previouisly on H&B rails. Relocated the 15mm pucks and fitted 3mm spacers( acrylic discs with appropriate holes drilled) to adapt to the 18mm rails, I also changed over from self tapping screws to nuts and bolts with nuts being recessed ). I'm left with 12 small drill holes ( about 6mm) which were in old location of pucks. Was wondering how best to block/fill them. Some of the holes coincide with the rails so cannot be covered by anything more than a fraction of a mm thick on the exterior. Was thinking, Gorilla tape on inside then fill the 2mm thickness of the hole with epoxy followed by gorilla tape on exterior, or maybe no tape on exterior as epoxy is filling the hole. Anyone got any other ideas, originally I had been thinking of using some reinforced plastic film ( same stuff used in damp proof course in walls) stuck on with siome sort of adheisive, however the gorilla tape seems like quite tough sticky stuff.

    Recessed holes look rough in photo but will have filling of black silicone eventually. White layer is adhesive on both sides of spacer, probably overkill but easy to do.
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    University of St.Helens Click here to find out how to Subscribe
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    10p coins stuck on the inside with Araldite.
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    because it's safer to harass rich women than motorcycle gangs.

  3. #3
    Destined to come last Click here to find out how to Subscribe
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    Pop rivet and washer
    Brian

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  4. #4
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    Quote Originally Posted by Oldrat View Post
    Pop rivet and washer
    I don't think they will work as it will be too proud with the rails sitting on the rivet.

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    Press in a bit of aluminium into each hole (just below the surface), a tight fit, and alu weld it from the outside and then grind / polish to a smooth finish.
    I've done it with stainless steel before so aluminium should be so much easier.
    "I must be traveling on now 'cause there's too many places I've got to see.

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    Duck tape each side. JJH

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    Pop rivets will not be waterproof. Use small pieces of cut aluminium glued in place, as mentioned Araldite works well.

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    Check out aluminium aircraft rivets on e bay , countersunk ones will be perfect

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    As they are only 6mm dia holes it would be easy to weld them up and grind them flush without having to insert any plugs.

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    Tapered rubber bung, waterproof glue, pull through wait till dry, trim off.

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    Ridiculous idea. You get much better coverage with a 2p. I know, used it on my Land Rover a few times.

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    Rubber grommets, Screwfix or Halfords......sorted

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    Park at top og waitrose/ and an void deep puddlrs?

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    Slightly Bevel the outside and inside of the hole then fill with epoxy,sand and paint as appropriate. Some clear tape on the outside will help whilst it dries

    Caution : May stop suddenly

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    Tape on the inside because if you weld the holes up you'll wreck the anodising.

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    Quote Originally Posted by Andi_archer View Post
    Slightly Bevel the outside and inside of the hole then fill with epoxy,sand and paint as appropriate. Some clear tape on the outside will help whilst it dries

    I fixed 4 drilled holes on my metal mules like that, didn't bother painting them just put a sticker over the repair, totally flush.

    JimmyMac

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