How to fill a hole in an aluminium sliding door frame?

[Sputnik]

I have replaced a sliding door lock (badly) but have to put one last screw into the aluminium sliding door frame... only problem is there is already a hole in the frame and it's larger than the screw. I can't use a bigger screw and there's no real access to behind the frame that i can easily work out. Is there some way i can 'fill in' the hole with something that's then strong enough put a screw into. (It doesn't have to be fort knox but would be nice if it was reasonably secure. I could potentially drill ANOTHER hole on the side so i could get a bolt behind it then fill THAT hole in... but honestly, i have no clue... obviously. This one's way out of my very limited expertise.

I bought some Selley's Plasti Bond Heavy Duty Bog but haven't used it before... any chance that will do the trick or is there something better to use? (There are a few other random holes in the door frame i wouldn't mind filling also while i'm at it.) And if it does work is it 'solid' enough tp push into the hole like putty or is there some other way of doing it?

[Noyade · Accepted solution]

G'day @Sputnik 

I may not be fully understanding of the lock tolerances and the issues involved.

But would a new matching length of flat aluminium pop riveted at the ends create a new 'canvas' for the lock's screws help?

I hope that makes sense.

Or a strategically placed nut rivet - there should be enough gripping power even with that 'slot.'

What is that slot width in mm?

I don't believe the "Bog" will adhere enough to the aluminium for a secure screw hold. But I have been wrong many times in life.

Random coffee thoughts on a rainy day. Cheers - keep us informed!

[Sputnik]

Thanks for this mate. Actually never used nut rivets before so will do some homework there. The other suggestion makes sense but might not quite work. I did think about cutting into the SIDE of the frame and sliding a new piece BEHIND the front with the hole in it... so a few ideas to consider here appreciate the tips.

[EricL]

Hello @Sputnik 

That is an excellent suggestion coming from @Noyade. Just to add to the suggestions made, I propose patching the surface with a Metal Mate 40 x 3mm 1m Silver Aluminium Flat Bar and fixing it in place using screws. You can then drill into the patch and mount the door hardware on top of it.

If you need further assistance, please let us know.

Eric

[Sputnik]

Thanks so much Eric. Appreciate this. 

[Sputnik]

Just want to say thankyou @Noyade, you absolutely nailed (nutted) it! Bought a Kinchrome nut rivet tool, and it was 100% perfect for the job and after mucking about trying to fix this thing for weeks, took me about two minutes once i had the right advice and tool. I am very, very grateful. I'm off grid out here and on a VERY steep learning curve having to do lots of stuff by myself for the first time and this advice was 10/10. Thankyou!

[MitchellMc]

Thanks for the update @Sputnik. It's superb to hear that @Noyade's advice was helpful!

Glad you got it sorted.

Mitchell

[Noyade]

I'm really glad ya got it sorted @Sputnik 👍

Just be aware of one problem with the nuts - if they're exposed to water and you want to remove the bolt regularly, put a little grease on the bolt prior to inserting. Prevents rust. With rust, the bolt can seize and with excessive counter-clockwise force - loosen the bind and the nut 'free-wheels.'

I learnt the hard way with a evaporative air-conditioner cover. I eventually had to cut the head off (with difficulty) to remove the cover and repair.

Cheers.