How To Repair Rust Holes In Sheet Metal

Put on goggles gloves and a dust mask for protection.

How to repair rust holes in sheet metal. How to repair rust without welding. Step 2 grind away any trace of rust primer and paint at least 4 inches back from the edge of the rust hole. In this video im showing you the process i use to do small rust repairs where a complete panel. Here s a few tips on repairing rust holes in car body panels.

Select a patch matching the type of metal you re repairing. The welding process actually adds new steel to the thin steel and can result in a repaired spot that is stronger than the original metal. The stitch method involves first making a few spot welds to hold the panel in place then adding short 1 inch stitch welds skipping about 4 5 inches then another and so on. Step 1 cut away any excess trim and loose debris from the area leaving enough metal to maintain the shape of the body.

After slicing the patches out with a cutoff wheel next came the bending hammer and dolly session until the patches matched the holes and fit snug and flush into the flanged seat. Patching a hole with body filler. I used a piece of pvc pipe a vice mount miniature metal break and body hammer kit test fitting with clamps was up next. Welding creates a lot of heat and the sheet metal will twist and band away from the heat.

Attach a 60 grit flapper wheel to a 4 5 inch angle grinder and put on your safety glasses. Protect yourself against the. How to fill rust holes in metal method 1 of 3. The most permanent repair to a hole in sheet metal is to weld the hole shut.

While sanding the rust.