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How to Fix Holes in Aluminum Door Frame : 6 Methods

How to Fix Holes in Aluminum Door Frame

Last Updated on November 12, 2022

Anyone who has ever had a hole in their aluminum door frame knows how frustrating it can be. Not only are they an eyesore, but they can also let in drafts and insects.

Although these door frames are durable, they are not immune to damage. Over time, dents and scratches can accumulate, and eventually, small holes may form. If left untreated, these holes can grow larger and cause serious damage to the door frame.

In this blog post, we’ll show you how to fix holes in aluminum door frames using easily-available materials. With a little time and effort, you’ll have your door frame looking good as new in no time.

Which Type of Hole Does Your Aluminum Door Have

Required Tools and Supplies:

  • Tape measure
  • Caulking gun
  • Caulk
  • Putty knife
  • Sandpaper
  • Paintable caulk
  • Drill Machine
  • Grinding machine (if required)
  • Paintbrush
  • Chisel and file
  • Clean rags

Proven Hole Patching Tips: Different Scenarios and Materials

Proven Hole Patching Tips Different Scenarios and Materials

Using Liquid Metals: 

If you have a hole in your aluminum door frame, you can easily fix it with liquid metal. Make sure the area surrounding the hole is clean by wiping it with a damp cloth. Then, apply a large quantity of liquid metal to the hole, using a putty knife or similar tool to spread it evenly.

Next, use a piece of sandpaper to smooth out the surface of the metal. Finally, paint over the area with a matching color of paint. This simple repair will make your door look good as new.

Using J-B Weld: 

J-B Weld is a two-part epoxy resin that is effective for fixing small holes in aluminum door frames. To use it, mix equal parts of the epoxy resin and hardener, then apply it to the hole with a putty knife.

The J-B Weld will be set in 4-6 hours, and it will fully cure in 24 hours. Following curing, you can sand and paint the surface to blend in with the surroundings. When used properly, J-B Weld is an effective and permanent way to repair aluminum door frames with small holes.

Use AlumiWeld Rods: 

AlumiWeld is a specially formulated alloy that can be used to join and repair aluminum without welding. It can be used to fix small hole like stripped screw hole, crack, or break in aluminum door frames. The rods are easy to use and require no special skills or training.

Simply melt the rod in a hot flame and then apply it to the damaged area. The alloy will quickly cool and harden, creating a permanent bond. AlumiWeld can also be used to fill gaps or voids in aluminum structures. It is an ideal solution for repairing damage caused by corrosion.

With AlumiWeld, there is no need to replace damaged aluminum door frames. The metal door repair will be strong and durable, preventing further damage and extending the life of the door frame.

Use Devcon Aluminum Putty: 

Devcon aluminum putty is a great way to patch aluminum door frames. First, sand the surrounding area with a wire brush or sandpaper to remove any loose paint. 

Next, mix the Devcon putty according to the manufacturer’s instructions. Once it is mixed, apply it to the hole and smooth it out with a putty knife. Allow the putty to dry for the recommended time before painting or sanding.

Use Bondo Filler: 

Bondo is a filler used to repair small holes in metal, wood, and other materials. It is made from a mixture of resin and fillers that can be shaped and sanded to match the surrounding area. A small hole in an aluminum door frame can be fixed with Bondo.

First, the area around the hole should be cleaned and sanded. Next, the Bondo mixture is applied to the hole and allowed to dry. Once dry, the Bondo can be sanded and painted to match the surrounding area.

Use Aluminum Bolts: 

This method will only work with an Aluminum door frame with a certain thickness and small holes as it depends on the diameter of the aluminum bolts available.

The first thing you want to do is drill and tap the holes. This will give you something to thread a bolt into. Once you have the holes tapped, you can tighten down an aluminum bolt.

Be sure to use a washer under the head of the bolt to prevent it from pulling through the metal. You may need to cut off bolt heads once it is tightened down. You can then grind it flush with the surface of the metal.

Types of Aluminum Door Hole

Types of Aluminum Door Hole

There are several types of hole that might be in your aluminum door frame. There might be a small, circular dent where something has hit the door. There might be scraping along the edge where the paint has been scraped off.

There might be a large dent where the door has been hit by a car or another heavy object. Or, there might be a hole that has been cut into the door, likely with a saw or other sharp object. The type of hole will determine the best way to fix it.

For Small Holes

To start, clean the area around the hole with soapy water and a scrub brush to remove any dust present. Next, use a putty knife to apply epoxy filler to the hole, leveling it with the surrounding surface.

Afterward, sand down the epoxy until it is flush with the rest of the door frame. Paint or varnish to protect your repair job from the elements. With these simple steps, you will quickly restore the appearance of your door frame.

For Large Holes

One of the most common places to find a hole in an aluminum door frame is at the bottom, where the weather stripping meets the door. The good news is that this type of hole is relatively easy to fix. The first step is to clean out the surrounding areas with a brush and soap.

Next, you will need to apply a generous amount of epoxy resin to the area surrounding the hole. Be sure to smooth it out so that it is level with the surrounding surface. Once the epoxy has dried, you can then apply a layer of fiberglass mesh to reinforce the area.

Finally, add another layer of epoxy over top of the mesh. Once everything has dried, you should have a strong and sturdy repair that will last for many years to come.

If the hole is too large, it may be necessary to use a piece of sheet metal to patch the hole. The sheet metal can be cut to size and then attached to the door frame using screws or rivets. Be sure to seal around the edges of the patch with epoxy or caulk to prevent moisture from getting in.


1. Can You Use Body Filler on an Aluminum Door Frame?

Can You Use Body Filler on an Aluminum Door Frame

A: It is possible to fill an aluminum door frame with body filler, but it is not always the best option. Aluminum is a soft metal, so it is easy to dent and scratch. Body filler can help to smooth out minor imperfections, but it is not as durable as other options.

For example, if you are repairing a dent in an aluminum door frame, you might want to consider using a patch of sheet metal instead of body filler. Sheet metal is much less likely to crack or chip than body filler, and it will provide a more seamless repair. In general, body filler should only be used on aluminum door frames as a last resort.

2. How Can I Prevent Holes From Forming in My Aluminum Door Frame?

A: To help prevent hole formation, it’s important to regularly inspect your door frame and look for any signs of damage. If you see any fraying or weakness, sand down the area until it’s smooth, and then apply a fresh coat of paint or sealant.

It’s a good idea to keep your door frame clean and free of dirt and grime. A simple wipedown with a damp cloth can help to remove any build-up that could potentially lead to holes forming over time.

3. How Do I Know if the Hole is Too Big to Fix? 

A: There are a few different ways that you can tell if the hole in your aluminum door frame is too big to fix. First, take a look at the size of the hole. If it is bigger than a quarter, it is likely too big to fix.

Also, try to push the aluminum door frame back into place. If it does not stay in place or if it moves out of alignment, this is another indication that the hole is too large to be repaired.

4. What Type of Patch Should I Use to Fix The Hole in Aluminum Door Frame?

When it comes to repairing a hole in an aluminum door frame, you have a few different options. One popular option is to use an adhesive patch. These patches come in a variety of sizes and shapes, so you can find one that perfectly fits the hole in your door frame.

Adhesives are also very easy to use, and they provide a strong bond that will last for years. Another option is to use a metal filler. These products come in a putty form, and they can be easily spread over your door frame’s hole.

Metal fillers provide a durable repair that will resist corrosion and wear over time. If you want a more permanent solution, you can always weld the hole shut. This method requires more skill and equipment than the other two options, but it will provide a completely sealed repair that will last as long as the door frame itself.


While it’s not difficult to fix a hole in an aluminum door frame, it is important that you take the necessary steps to do so properly. In this article, we have outlined a few different methods you need to take to fill and repair aluminum door frames.

Any of these methods will give you a strong and lasting repair for your aluminum door frame. We hope that you found this information helpful and will be able to use it to fix your door frame properly. Thank you for taking the time to read this article.

Relevant Article To Read:

How to Fix Holes in Aluminum Door Frame : 6 Methods

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