How To Fix Broken Metal Without Welding? (5 Best Ways)

Have you ever found yourself wondering how to put together two pieces of metal without the need to go to a shop so they can weld it for you? Let’s say that your metal chair is old and one of the legs broke, and you have a family dinner.. . What are you going to do?

Here are some methods you can use if you find yourself in these situations. 

There are many ways you can handle a situation where you need to either put together two pieces of metal and need an alternative to welding.

There are also different types of metal, so you should be aware of what you are dealing with to do the best job possible. 

In this article you will learn how to fix a broken metal without welding.

1. Cold Metal Stitching

Cold metal stitching is a method to repair either sheet metal or two pieces of metal. With complex metal stitching, specialized inserts are implemented, which will join the metal piece back together. Cold stitching is an excellent method as an alternative since it is a simple process. 

High-strength metal is something people struggle to work with, but luckily for you, cold metal stitching is a method that will help you deal with it. High-strength metal is significant in complicated metal stitching.

Cold metal stitching requires a set of steps to make it work. Below are the steps for cold metal stitching.

  1. Diagnosis of the metal crack 
  2. Drilling the first holes
  3. Connecting the rows of holes
  4. Inserting the metal “keys” or Stitching
  5. The sewing between the stitches
  6. Finishing steps

2. Epoxy

This method might be the most popular for beginners. When trying to fix a metal without welding, there are many different ways, but this might be perfect for you if you are looking for a simple process and a cheap process. However, you might want to carry on with this method if you are looking for a temporary solution.

Epoxy putties are a fast way to deal with this problem. When you need to put together two pieces to make it one metal piece, epoxy putties are a method you should consider. Metal bonds might be easy, but when you are looking to achieve a permanent adhesive on the entire surface, you need to be sure that it is not a weak bond; otherwise, your repair will fail.

Epoxy Putty is commonly used for cracked cast iron pieces. You can find different options such as Quick Steel or JB Weld.

If you are looking for a cheap and fast solution, don’t hesitate to use epoxy putty. Epoxy products are easy to find because you can find them everywhere. Also, epoxy adhesive is pretty effective when dealing with small pieces. If you need to work with a piece of metal that is heavy and big, you might want to use a strong adhesive instead of epoxy for metal. 

3. Cheap and Homemade Solutions

Sometimes you don’t have time to go to the store to buy what you need and so you are looking for a more immediate solution with homemade products. 

Did you know that you can fix broken metal with warm water?

Let’s say that you need to put together two metal surfaces; you can fill a bowl with warm water and then add some liquid dish soap. By doing this, you will be able to put together two pieces of metal, but first, you need to give it time and let it dry.

Drying times are essential in any metal to metal bonding. If you are trying to fix metal items and make them a solid bond, make sure you use the proper method and give it time.  

4. Super Glue

When dealing with these kinds of issues where you need to put together two metal pieces or fix one, weak spots are not an option. High-strength metal is something people struggle to work with, but cold metal stitching could be helpful, as stated before. 

Glue for metal, such as super glue, might be a solution when working with small metal sheets or a small surface; but you might want to try something else when dealing with heavier giant metal. 

5. Metal Locking

Metal Locking is an alternative variation for the metal stitching method. This method focuses on repeating fractures to castings without the use of heat. As with other methods, metal locking requires a set of steps to make it work. There are five main steps, and these are the following: 

  1. Examination and preparation
  2. Drilling and fitting 
  3. Connecting the holes and inserting the metal lock keys
  4. Applying pressure-tight joint 
  5. Finishing

As you may notice, these steps are similar to those in the cold metal stitching process.

Metal locking is used in situations where heat is not an option or welding cannot be used. It usually is used when dealing with large structures such as engine blocks. 


Essential Safety Precautions in Metal Repair Work

When dealing with metal fixing, you need to be sure you are safe, and you are not risking your eyes or fingers/hands in the job.

When it comes to taking care of your eyes, safety glasses are a must. Every time you are working, you will see some pieces flying around or even sparks. 

Another thing you have to take care of is your hands and fingers. You might be working with superglue, and so you will need to protect your hands. I believe leather work gloves are a big help, and you will feel safer if you use them. 

Final Words

As I said before, what if you are looking to repair a chair for a family dinner? Or you are in need to repair sheets of metal, and you can’t use a welder?

You have read about the most commonly used methods when dealing with a metal fixing issue. If you happen to find in any of these situations, now you have an answer! Either if you are looking for a cheap and homemade or even if you are looking to fix a metal piece in a factory! 

Everything you need to know is here!