The heating torch is used for heating solder and maintaining its
temperature at a level of consistency for proper application. This
consistency resembles that of drywall plaster. Caution should
be used in controlling the workable temperature of the solder.
Non workable and non spread able solder material results from too
low of temperature. Temperatures that are too high result in
solder material sagging or running off from the area to be repaired.
Again, torch flame must have medium to low "feather" and not be too
Hammer, file, Small Punch, Orbital Sander:
When preparing the sheet metal for solder repair, the damaged area
must be repaired prior to solder application. This includes the
repair of high and low area (dings, dents) surrounding the immediate area
to be repaired including the specific location of the damaged area.
The Damaged sheet metal should be repaired as close to flush as possible
with undamaged surrounding area, leaving a downward taper 1/4" to 1/2"
from the edge of the damage to be repaired. The area to be repaired
will serve as an anchor for the solder repair and allow surfaces to be
finesse-sanded flush to the surrounding surface. The surface should
also be sanded to remove any oil or surface debris prior to flux
Solder flux is applied to the damaged sheet metal area to act as a
bonding agent between the sheet metal surface and the solder material.
Molten solder will not bond to a prepared sheet metal surface without
proper flux application. The type of flux to be used will be
determined by the damaged area to be repaired.
The heavier solder-based tinning flux is to be applied to areas of
large or extremely damaged sheet metal. This tinning flux is
corrosive and may cause burns if it comes into contact with skin or eyes.
Therefore, caution should be used in its application to damaged area. The
use of a small brush will be necessary. After application, the area must
be heated until the solder-based flux blackens on the surface. Then the
area must be heated until the solder-based
Light Solder Paste Flux:
The solid core wire solder paste is the same type used when making
electrical connections. This flux also acts as a bonding agent
between the surface to be repaired and the solder material. However,
this paste flux is generally used only for small spot applications.
Unlike the heavier solder flux that needs to be primed with heat and wiped
before solder application, the heat used to apply the wire solder material
will be sufficient to establish the bond necessary for its application.
Wooden or Fiberglass Solder Wiping Blade With Beeswax Tray:
A wooden or fiberglass solder wiping paddle is used for spreading and
smoothing the surface of the workable molten solder. A coating of
melted beeswax on the surface of the paddle will aid in preventing the
molten solder from sticking to the paddle surface and ease the ability to
spread the molten solder material across the damaged metal area being
Solder Repair Process Procedure:
With all preliminary steps achieved, the desired solder material is
heated and applied to the pre-tinned and prepared surface after reaching a
low temperature melting point. The material is then smoothed beyond
the tapered area by 1/4" to 1/2" surrounding the surface to be
repaired while adding enough molten solder material to achieve uniform
level between the damaged area and the non damaged metal surface.
With this completed, water may be applied to cool the molten solder
material in order to "set" the solder repair. The material
should then be filed and /or sanded to become level with the surrounding
surface. Pitting of the solder surface may occur if foreign matter
(dirt, metal debris, air pockets) is present during the molten solder