How To Repair Rust Holes In Sheet Metal

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How to repair rust holes in sheet metal.

Step 1 cut away any excess trim and loose debris from the area leaving enough metal to maintain the shape of the body. 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. Select a patch matching the type of metal you re repairing. This reduces the amount of heat each area is exposed to.

How to repair rust without welding. The complexity of welding increases as the thickness of the material decreases. While sanding the rust. 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.

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. How to fill rust holes in metal method 1 of 3. I used a piece of pvc pipe a vice mount miniature metal break and body hammer kit test fitting with clamps was up next. The most permanent repair to a hole in sheet metal is to weld the hole shut.

Welding creates a lot of heat and the sheet metal will twist and band away from the heat. Step 2 grind away any trace of rust primer and paint at least 4 inches back from the edge of the rust hole. Attach a 60 grit flapper wheel to a 4 5 inch angle grinder and put on your safety glasses. 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.