TearDrop Repair - and what not to do...

[doug hodder]

A thickened epoxy with a fairing filler will take care of that along with some touch up paint. Work it just like a bondo, with the sanding and paint. Don't do a polyester bondo on it, just my opinion. Cheaper than all aluminum at this point. Was that wall pressured from a bulkhead that was a bit too wide? Also, Chinese ply, it it was used, can have crappy filler laminates in it. I've done pine struts on a lot of my builds with no issues like that, and they all have been epoxy over ply, some with 1/4" roofs. Doug

[greekspeedoman]

A small crack that did a lot of damage huh? Sorry about that.

I think I'd patch that spot like you would a hole in drywall. Square it up, put some additional pieces inside the wall to help with your joints and patch it. I'd use some gorilla glue. Sand even, then epoxy. Aluminum over the top. That spot isn't structurally critical, so a simple patch should work and won't be an eyesore under the aluminum skin.