Patching Rust Holes With Sheet Metal

Insert the metal mesh behind the rust hole.

Patching rust holes with sheet metal. By filling in holes you stop rust in its tracks and ensure the metal lasts longer. And butt up to the edges of the hole. I used a piece of pvc pipe a vice mount miniature metal break and body hammer kit. 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.

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. Thin steel often called sheet metal is used in innumerable objects. I then used the templates to trace out the patch panels on some sheet metal. Cut the affected metal away from the hole with tin snips or a grinder.

Hold the zinc metal piece behind the hole and attach it to the body of the vehicle behind the hole with small amounts of filler. Even banging on it will make you think you are banding on sheet metal. All of the rust needs to be removed from the hole and the metal surrounding it. You need to be able to weld thin sheet metal and.

Most kits contain a body filler paste a hardener and a piece of expanded zinc metal or fiberglass cloth which is used to support the filler while patching the hole. Body filler is a simple way to repair freshly cleaned holes. In some of these applications the chances of needing to ever repair a hole in the metal is remote. Coat the area inside the hole thoroughly with miracle paint to prevent further rusting then make a patch of 3 layers of fiberglass mat soaked in miracle paint and apply it over the rust hole.

In others particularly in outdoor applications abuse accident rust or other incidents can occur. Small rust holes offer beginners a great way to practice rust repair. When dry overnight you will not believe how strong this repair. Rust on your classic muscle car is a nuisance.

While replacing large sections can be relatively easy the smaller rust holes that do not warrant a full panel replacement are small enough that the average builder can tackle them and be back inside in time for dinner.