How To Repair Rust Holes In Sheet Metal

Here s a few tips on repairing rust holes in car body panels.

How to repair rust holes in sheet metal.

Attach a 60 grit flapper wheel to a 4 5 inch angle grinder and put on your safety glasses. While sanding the rust. I used a piece of pvc pipe a vice mount miniature metal break and body hammer kit test fitting with clamps was up next. Patching a hole with body filler.

Welding creates a lot of heat and the sheet metal will twist and band away from the heat. Protect yourself against the. Pull the trigger of the angle grinder and run the spinning 60 grit flapper wheel over the rusted area of the metal. How to repair rust without welding.

This reduces the amount of heat each area is exposed to. 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. Put on goggles gloves and a dust mask for protection. How to fill rust holes in metal method 1 of 3.

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 complexity of welding increases as the thickness of the material decreases. Select a patch matching the type of metal you re repairing. 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.