It’s inevitable that at some point while removing your delicate emblem from your classic car, a mounting stud (or six), break off. Many will resort to using JB Weld or other epoxy to re-affix their studs. Unfortunately this type of repair is prone to fail. Others simply grind off the nubby stud remains and then use double sided tape to secure their emblems…

Well, there is another way – a better way. It’s inexpensive, easy,  and is permanent. The following repair is perfect for emblems made from aluminum, zinc, and/or pot metal. I’ll be repairing my Volkswagen emblem that is made from aluminum.

Here’s a list of needed supplies:

• your broken emblem
• 7/64″ drill bit and drill
• Stainless Steel wire brush (toothbrush size from the Dollar Store)
• Propane torch
• 1/8″ aluminum rivets
• Wire cutters
• Small file or Dremel tool
• 220 grit Sandpaper
• One or two rods of
  ALUMALOY 10 Rods: Aluminum REPAIR Rods No Welding Fix Cracks Drill Tap Polish or Paint

 

The Alumaloy (abt $10) is an inexpensive soldering rod that works well with aluminum and pot metals. What’s nice is it melts to flow at 730º F, far below the melting point of aluminum. It also offers a 45,000 PSI tensile strength which is fine for our emblem’s needs.

Step one:

File flat any old broken stud bases.

Step Two:

After filing smooth any proud stud bases, use the 7/64″ drill to form a hole about 1mm deep.

Step Three:

Using the stainless steel brush, thoroughly clean the drilled area.

Step Four:

Take the torch and heat up the emblem in the drilled out area. Heat slowly and evenly.

Step Five:

Apply the Alumaloy with a light brush motion. As it melts apply just enough to fill the drilled hole. Also, take the rivet end and after wire-brushing the end of the rivet, apply the Alumaloy to “tin” it.

Step Six:

Press the tinned portion of the rivet on the emblem as you apply heat. When the Alumaloy melts the rivet end should sink into the emblem’s drilled defect. Let cool slowly, don’t’ quench.

Step Seven:

Snip the rivet to desired length leaving your new stud. Use the file or a Dremel tool to grind away excess Alumaloy at the rivet base.

Step Eight:

Align the studs to the vehicles mating surface and ensure it sits flush.

Done!