Boris113 Posted January 30, 2015 Share Posted January 30, 2015 During the rebuild of the 90 funds ran a bit tight and I couldn't afford to buy an exhaust system. Instead we cobbled some stainless pipe and lengths of flexi together and made a side exit that came through the side of the rear tub between the passenger door and the rear wheel. It has no silencers so is deafening for the passenger and the flexi has now fallen apart (held together with a baked bean tin and jubilee clips) so I'd like to remake the exhaust properly and move the exit to the rear corner, behind the nearside wheel. The problem is that there will be a 3 inch hole left in the side of the rear tub from the previous system. Does anyone have a cunning suggestion as to how to cover it up neatly? I thought of a painted plate behind and some rivets but it will still be noticeable. Thank you, Harry Quote Link to comment Share on other sites More sharing options...
robertspark Posted January 30, 2015 Share Posted January 30, 2015 I would have said the propper way to do it is to cut an ally circle of size slightly smaller than the hole to be filled and tig stitch weld it using something like those Eastwood panel welding clamps, then flap disk or sand it smooth and level Using a bit of ally from an old panel https://m.youtube.com/watch?v=OkFhfKcjbQQ But never tried it myself plus not sure what tools you have to hand Quote Link to comment Share on other sites More sharing options...
muddy Posted January 30, 2015 Share Posted January 30, 2015 Sikaflex some chequerplate across the back of the hole and fill? It all depends how good a finish you require. Or fill it with anything you can find and put a large sticker over the area. Will. Quote Link to comment Share on other sites More sharing options...
dave88sw Posted January 30, 2015 Share Posted January 30, 2015 I'd cut some ali slightly larger than the hole and stick it on behind with sika/tiger seal, then skim it with filler and paint. Done well you'd not know there was ever a hole and as the ali is only about 1mm thick anyway, the filler really will be just a skim. Quote Link to comment Share on other sites More sharing options...
GW8IZR Posted January 30, 2015 Share Posted January 30, 2015 with a bit of care you can jog an edge on a disk, 3m bond it in place from behind, thin skim and paint. Only you would ever know its there. Quote Link to comment Share on other sites More sharing options...
Mo Murphy Posted January 31, 2015 Share Posted January 31, 2015 If you can't hide it make a feature of it. Use it as a portal to another dimension or perhaps grow a Virginia Creeper through it, though you'd have to find some way of mounting a flowerpot behind the panel. ? Mo 2 Quote Link to comment Share on other sites More sharing options...
ballcock Posted January 31, 2015 Share Posted January 31, 2015 Get one of those blingy 3" chrome end pipes and stick it through the hole and you can have the same effect as the spotty gits with their 1100cc Corsa's get. Then you can cruz the local car parcs. Innit? Quote Link to comment Share on other sites More sharing options...
slomofo Posted January 31, 2015 Share Posted January 31, 2015 Two options: 1) Make the edges ragged and turned in, burn it it a bit and call it shell damage? 2) more practical, use the bit you cut out for the new hole mounted on a backing plate to fill the old one, rivet bondo and paint Voila! Quote Link to comment Share on other sites More sharing options...
Team Idris Posted January 31, 2015 Share Posted January 31, 2015 You need the aeroplane way to fix it. They do this fix day in, day out to fix holes from debris. First thing is make the hole round (you already have that part). Then place the same gauge ally behind the hole and scribe a line onto it. Then cut it out so it fits the hole perfectly. Then cut a disk of ally that is bigger and attach it to the inside face (they use an epoxy glue). Then fill out the depth with the bit you cut to fit the hole. I'd use filler for the glue. Or drill three pop rivet holes through the circumference of the 3" hole so the rivet locks all three sheets together. Quote Link to comment Share on other sites More sharing options...
Team Idris Posted February 1, 2015 Share Posted February 1, 2015 I was sure there would be a vid on it on You tube, but I typed in everything I could think of like 'doubler' and aluminium composit wing and got nowhere Quote Link to comment Share on other sites More sharing options...
Boris113 Posted February 5, 2015 Author Share Posted February 5, 2015 Thanks for the suggestions everyone Sadly I dont have TIG so that is out of the question. Bonding a piece of ally behind and then the smaller disk inside sounds like a fairly invisible solution. Best of all I can spray the part before I glue it so wouldn't need to spray the whole side of the tub. If all else fails then Mo's cunning solution should do the trick...I think I'l borrow a flower pot from my grandmother and zip tie it to the rock slider, covering the hole quite nicely. It's not dissimilar to JLR's current CO2 offset scheme! Harry 1 Quote Link to comment Share on other sites More sharing options...
Anderzander Posted February 5, 2015 Share Posted February 5, 2015 Failing those a large sticker or some Land Rover wall paper. Quote Link to comment Share on other sites More sharing options...
tel.350 Posted February 5, 2015 Share Posted February 5, 2015 I have a very good condition side exit exhaust in the shed going cheap, free set of earplugs included. Terry Quote Link to comment Share on other sites More sharing options...
Mo Murphy Posted February 6, 2015 Share Posted February 6, 2015 A clematis is a viable alternative, Harry, and as a bonus it flowers but is not as vigorous as a Virginia Creeper so will take longer to cover the hole. HTH Mo 1 Quote Link to comment Share on other sites More sharing options...
pw8757 Posted February 6, 2015 Share Posted February 6, 2015 You say you can't TIG weld.....I'm having some success with a Laser product from Machine Mart which is like solder for aluminium. https://www.machinemart.co.uk/shop/product/details/aluminium-repair-starter-kit?da=1&TC=SRC-aluminium%20weld You can use a blow torch to join aluminium. I've found it to be strong and effective. Also available (cheaper) on EBay - search under HTS 2000. You'll see videos about it on YouTube as well. Quote Link to comment Share on other sites More sharing options...
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