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Rust hole repair sheet metal.
A rust hole compromises the structural integrity of the 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.
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The first step was to cut out the rust.
And butt up to the edges of the hole.
Then go back toward the center of the hole scrubbing with heavy pressure to eliminate the rust.
Weld the most permanent repair to a hole in sheet metal is to weld the hole shut.
To make the repair as effective as possible scrub away the paint up to 1 in 2 5 cm beyond the edges of the hole.
Easy to do and really strong.
Keep sanding until you re able to see bare metal.
And maybe the epoxy would result in a more rustproof seam.
Welding in patch panels with a flux core welder without a gas envelope is an exercise in burn through and swearing so glue it was.
Another good idea when replacing any type of sheet metal is using weld through primer.
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.
Cut the sheet metal back until all of the rust around the hole s perimeter is no longer visible.
Check out how you can repair rusted sheetmetal by using patch panels as shown on this 1969 camaro.
This setup removes the remaining rust and would allow us to cut the hole to an easily patchable size and shape.
All of the rust must go.
We have a huge selection of high quality rust repair and auto body panels including rockers cab corners wheel arches fenders and more.
Universal sheetmetal repair panels available at low prices.
Repairing rust or a rust hole on metal without welding requires a material that bonds and is as strong as metal.
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A plasma cutter reciprocating saw or die grinder can also be used for this step.