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I have a piece of sheet metal flashing I would like to extend by about 6". Due to its installation, it would be impractical to remove it and put a new piece that is of the right size, so a functional work-around might be to seam another piece to it.

What is a good way to join two pieces of sheet metal? Can I lap them by a couple of inches and then use some kind of fastener (rivet?) every few inches along the seam?

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  • Picture? Size? What is it on top of?
    – manassehkatz-Moving 2 Codidact
    Commented Jan 29, 2021 at 3:07
  • This is a very general question. Imaginr two pieces of 2x2 sheet metal that you want to join to form a 2x4 piece
    – amphibient
    Commented Jan 29, 2021 at 3:09
  • It's aluminum flashing like you would use for roofing, windows etc
    – amphibient
    Commented Jan 29, 2021 at 3:10
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    This is a very general question. That's actually the problem. Tell me you want to connect two heavy sheets of steel and I might say weld them. Two sheets of aluminum maybe not. Attaching when one is already installed limits options more, depending on where it is installed, etc.
    – manassehkatz-Moving 2 Codidact
    Commented Jan 29, 2021 at 3:17
  • 1
    So you (probably, but you're carefully avoiding giving enough detail to answer) need it to be watertight - such details matter. And likely the piece that's in place can't be bent to form a proper lock-seam, but you haven't provided a picture.
    – Ecnerwal
    Commented Jan 29, 2021 at 4:09

1 Answer 1

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Pop Rivets

The easiest way would be with a pop riveter.

  • Clamp the two pieces together. Drill a hole for the rivet. Install one rivet.
  • Repeat this for a rivet at the other end.
  • Drill all the inbetween holes.
  • Run a strip of thin cardboard between the sheets from the uphill side to get out any shavings you missed.
  • Rivet the remaining holes.

I suggest practicing on scrap. A pop rivet has one side that doesn't look bad, but isn't pretty from the other side.

Epoxy

A second easy way is with epoxy. Read the labels and get one matched to your metal.

Epoxy needs clean metal to bond to. It also helps if it has some tooth.

  • Do a dry run so that you know your clamping system works. You can test it by clamping with a few strips of paper between the sheets. If you can pull out any of the sheets, you need to redesign.
  • Mark the limits of where you want the pieces to align with a scratch using a utility blade. You do not want to go through the paint or galvanizing if present.
  • use a 100 grit sanding sponge to rough up the surface and take off the shine.
  • wash once with tri sodium phosphate, 1 tablespoon in a quart of HOT water.
  • Rinse with clean water.
  • Allow to dry.
  • Wipe with an acetone soaked cloth. (Caution moderately toxic and very explosive fumes.)
  • Let dry. (Won't be long)
  • Mix up your glue. DO THE FULL MIXING TIME
  • Apply your glue in a thin layer to both surfaces. A wood coffee stir stick works well as an applicator.
  • Clamp the pieces together.
  • Remove any glue that squeezes out.

You can try using construction adhesive meant for non porous surfaces. This is hard to squeeze flat for a short joint, but it may be more tolerant of temperature changes or outdoor use.

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2
  • Yep, I think rivet is it
    – amphibient
    Commented Jan 29, 2021 at 4:39
  • You missed a sure win: combine epoxy and pop rivets! +1
    – fred_dot_u
    Commented Jan 30, 2021 at 2:05

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