Patching Rust Holes Sheet Metal

I found under the outer layer of metal what i thought were additional layers of rusted chipping metal was actually dense foam padding.

Patching rust holes sheet metal.

The complexity of welding increases as the thickness of the material decreases. Reach underneath the metal if you re able to or push the patch through the hole. Then enlarge the sanded area so you ll have space to feather the edges. Complete the feathering with 220 grit.

Another good idea when replacing any type of sheet metal is using weld through primer. Did you want to learn how to work around that and deliver a solid re. I used a piece of pvc pipe a vice mount miniature metal break and body hammer kit. The patch should completely cover the hole.

Sand through the rust spots down to bare metal. I scraped the rest of the metal chips off of the foam. Scrape and sand the first step was to scrape off the loose paint surrounding the rust spot and to sand off most of the rust. I then used the templates to trace out the patch panels on some sheet metal.

Screwdrivers putty knives etc this just scratches the paint and allows more rust to form. Insert the metal patch behind the hole. Then spread the patch out so it s flat against the remaining metal. 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.

This high zinc paint helps protect the backside of the sheet metal from rusting a very important step in the restoration process this is something most people forget and they end up with rust bubble just a few years down the road. Have you ever welded something so thin and worn out that all you do is blow holes in it. Keep it stuck in place by spreading a little bit of the body filler around its edges. Cut the affected metal away from the hole with tin snips or a grinder.

If you don t have a grinder or angle grinder you can use heavy duty tin snips to cut the rust and rusting metal out of the hole. All of the rust needs to be removed from the hole and the metal surrounding it. 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. Switch to 120 grit sandpaper to feather the edges of the repair area.