How to Repair a Small Hole on My Aluminum Patio Awning

Aluminum patio awnings are susceptible to the development of small holes due to weather and normal wear over time. You don’t need to replace the entire awning if you have just a few small holes. Instead, patch and repair the holes using an epoxy designed to work with aluminum and metals. Metal epoxy can be found at most hardware stores.

Clean rag
Metal epoxy
Putty knife
240-grit sandpaper
Tin strips
Electric metal shears
Butyl tape
Metal paint

Instructions

- 1
  Locate the leak or crack.
- 2
  Wipe down the aluminum patio awning around the hole using a clean rag to remove any dirt. Sand down the surface using a 240-grit sandpaper. This creates a rough surface for the putty to adhere to.
- 3
  Mix the metal epoxy according to instructions on the packaging.
- 4
  Apply the epoxy to the hole using a putty knife. If the hole is larger than the size of a quarter, use tin strips to patch the area. Tin strips can be purchased from most hardware stores. Cut the tin strip with a pair of electric metal shears for a custom fit over the hole. Place butyl tape around the perimeter of the back side of the tin. Press the tin firmly in place over the hole.
- 5
  Smooth out the epoxy and remove any excess.
- 6
  Wait 24 to 48 hours for the epoxy to dry completely and examine the hole.
- 7
  Reapply metal epoxy until the hole is patched completely. Sand down the surface of the epoxy using a fine grit sandpaper to smooth out any rough spots. Apply paint designed for metal that matches your aluminum awning.

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