WonderPatch Installation Instructions

Even though patching a hole is an ordinary task, WonderPatch™ Hole Repair is a high-tech product and you should use it according to these directions to get the best results. Please read all the directions before you begin.

WonderPatch™ Hole Repair can be used to fix holes in hard flat surfaces or hard surfaces that have curves or irregularities. It is not suitable for fixing holes in flexible surfaces such as tarps or tents.

DO NOT use WonderPatch™ Hole Repair for vessels, or for things that contain or may in the future contain volatile, flammable, or hazardous materials!

Download Instructions: WonderPatch-Instructions.pdf (275 KB)


  1. Select a patch that overlaps the hole by at least 1 inch on all sides. If you need to use more than one patch, overlap the patches by at least 1 inch and lay them on from the bottom up and from the front toward the rear or contact us to inquire about Shop Pack custom lengths of the same great WonderPatch™ material. If there is anything sticking up in the area you intend to patch, hammer it down so that the patch can lay reasonably flat. It does not need to be perfect. Rivets are OK as long as you have the patch overlap them by at least 1 inch. There is no need to hammer rivets down. WonderPatch™ Hole Repair will form around them well.
  2. Thoroughly clean the area around the hole you will be patching. First, completely wipe off any loose dirt using a cloth or paper towel. (If there is rust or loose paint, it MUST be removed.) Use a little window cleaner or hand soap if you wish but be sure to rinse any soap off very well and allow the surface to completely dry. DO NOT use any petroleum-based cleaners such as kerosene or diesel fuel because they will leave a film on the surface that will keep the patch from sticking as well as designed. As a last cleaning step, vigorously wipe the surface with a 50% solution of isopropyl rubbing alcohol or use the alcohol prep pad that came in the WonderPatch™ Hole Repair Kit. Allow to dry.
  3. CAUTION: once the WonderPatch™ Hole Repair is attached to the surface, it might not easily be lifted back off and repositioned. Therefore, make sure you know right where you mean to stick it. We suggest you draw an outline to guide the application as follows: without exposing the adhesive, hold the patch in place over the hole and trace around it. Lift the patch away and check to be sure the outline is level and that the patch will overlap the hole and any rivets by at least 1 inch.
  4. Peel the liner off the adhesive while holding the patch by its edges. The adhesive will not come off on your hands or clothing but touching it with skin or cloth may leave a residue that is undesirable. Carefully align one edge of the patch with the traced guideline you made in step 3 and lower the rest of the patch onto the surface.
  5. Once the patch is in position, press it down with sustained firm pressure using your fingers or the heel of your hand. Work from the first edge to the edge on the opposite side. If there are rivets or other irregularities, give the patch longer, stronger pressure over those areas to let the patch conform to the rivet or irregularity.

Painting WonderPatch™ Hole Repair

The special white finish applied at the factory is designed to withstand harsh weather and road grime as well as strong detergents. Therefore, you will need to be careful in applying other paint to the surface to get good results. If you can spare the time, it is easiest to paint the patch before you apply it so you won’t need to mask it off to avoid overspray. If you must delay the painting, there is no harm done; just follow these directions later.

  1. Be sure the liner is fully in place so that the adhesive is not exposed.
  2. Rough up the factory-applied surface using fine (150 grit or finer) sandpaper. It is not necessary to completely remove the factory-applied finish.
  3. Wipe the surface of the patch with paint solvent or alcohol to remove any dust or sanding debris.
  4. Paint the patch surface with high quality aerosol paint using several light coats rather than a heavy coat.
  5. Allow the paint to dry thoroughly.

If you are covering irregularities

Except for rivets or bolt heads, if something is sticking up into the area where you intend to apply the patch, knock it down as much as you can. For the best seal, it is better to have the patch area dented in a little rather than sticking up. The surface does not need to be perfectly flat. WonderPatch™ Hole Repair is made of sturdy, heavy gauge aluminum that can bridge across irregularities. If you cannot avoid having a rivet or something else sticking up at the edge of the patch (rather than 1” in from the edge), you will get the best results by forming the WonderPatch™ Hole Repair patch to the shape of the surface before you adhere it; and make the edge with the rivet the last one you press down. Then be sure to use extra force on that edge to be certain the adhesive forms well around the rivet. Tapping gently around the rivet with a light hammer works well to conform the edge of the patch.

If you are patching a curved surface

CAUTION: A compound curved surface is one that curves in two directions; for example, a football curves over as well as around. WonderPatch™ Hole Repair is not intended to be used to fix tight compound curved surfaces. If you wish to try to use WonderPatch™ for this purpose, try to use a patch that is just 1 inch larger than the hole in each direction; trim it to the proper size using tin snips or sturdy scissors. Any excess length or width will tend to fold and stand off from the surface forming a less effective seal. Some users have reported success by cushioning the adhesive and then pre-forming the patch into shape over a rounded surface using a hammer to cup the patch into shape. Round the corners to avoid snags.

Simple curved surfaces (like a tube) are easily patched using WonderPatch™ Hole Repair. You will find it easier to patch curved surfaces if you form the WonderPatch™ Hole Repair to the shape of the surface before proceeding.

For a convex curved surface like the outside of a pipe (where the patch will go OVER the curve), form the patch over a cylinder slightly smaller than the curve so that the curve of the patch is just a little tight. Then, when you apply the patch at the edge of your outlined area (see step 4 at the top of this sheet) you will need to hold it open a little as you lay it down so it will stick over the entire area. If you pre-form the patch too loose, it will tend to try to pick up at the edges.

For a concave curved surface (where the patch will lie IN the curve), pre-form the patch over a slightly larger cylinder so that its curve is a little looser than the surface to be repaired. Then, when you apply the patch at the edge of your outlined area you will need to spring it inward as you lay it down over the entire area. If you pre-form the patch too tight, it will try to pull away at the edges.