Galvanic Corrosion - Hinge Patch Solution

To work on our door, it was removed from the shell, exposing hidden galvanic corrosion.  The aluminum and steel support behind the upper hinge were both badly damaged.  Repairs will be done in place as we are not replacing the upper curb side panel, and there is no other reason to remove the aluminum skin.

A patch was cut and laid inside the wall, positioned with cleco fasteners.

 

Inside the wall, a thick aluminum patch is bent on one side and is securely attached to the supporting aluminum wall stud.

The hinge is positioned onto the new aluminum patch before it is riveted.