How to Repair an Aluminum Painted Roof

Aluminum roofing is typically found in outbuildings such as detached awnings and sheds. It is sometimes painted for a more distinct look or to provide an extra layer of protection against the weather, making the aluminum material more impervious. If you have a painted aluminum roof and there is a hole causing a leak, you can repair it yourself. In fact, the process is not unlike repairing aluminum on an automobile or boat.

Rubber gloves
Wire brush
Paint thinner
Steel wool
Sandpaper
Bucket
Sponge
Cold-weld kit (epoxy resin and hardener)
Putty knife
Alkyd primer
Paintbrush
Enamel paint

Instructions

- 1
  Put on rubber gloves and brush over the damaged spot on your painted aluminum roof with a wire brush to knock off any surface dirt, rust or corrosion.
- 2
  Pour a small amount of paint thinner over the same area you brushed, then scrub vigorously with steel wool to remove any paint. Abrade the same spot with sandpaper once most or all of the paint is taken off.
- 3
  Fill a bucket with plain water and rinse the cleaned spot with a sponge to get all the chemicals and dust off the aluminum roof. Let the spot air dry before proceeding.
- 4
  Squeeze equal amounts of epoxy resin and hardener from their respective tubes directly over the hole in the aluminum roof and smooth it with a putty knife. Allow the patch to harden for about five hours.
- 5
  Apply a coat of alkyd primer over the patch with a paintbrush and let it dry for about three hours, or as long as directed by the manufacturer.
- 6
  Apply at least two coats of enamel paint in a matching color; wait about two to three hours between each coat. Let the paint dry completely to finish the repair of your painted aluminum roof.

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