How To Replace Rusted Sheet Metal

You can t just mask over it but have to remove it completely and replace the section with new sheet metal.

How to replace rusted sheet metal.

Sheet metal is a huge part of any hotrod build or autobody repair. 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. A 36 grit sanding disc works best. This article is aimed at generally taking you through the steps of removing the old rusted metal and replacing with new 22 gauge sheet metal which is a typical gage for general body repair for smaller panels and sections.

A rust hole compromises the structural integrity of the metal. Here is a tutorial how to video that show. If the metal around any fastener has rusted and a hole has developed repair the rusted hole before. I then used the templates to trace out the patch panels on some sheet metal.

Use an air sander to quickly bring the rusted area down to bare metal. You should now have a shiny solid rust free surface. Repairing rust or a rust hole on metal without welding requires a material that bonds and is as strong as metal. Remove rusted screws expect to find at least a couple of corroded screws when you work on older metal furniture and appliances and overcome these obstacles by following the screw removal.

How to repair rusted metal without welding. Sand beyond the rusted area an inch or so. When water contacts bare metal rust forms on the surface of the metal. Once down to bare metal all the damage is revealed.

Whether you re fixing a dent rust hail etc. Clean the exposed metal area with a 60 or 80 grit disc. Remove any rusted screws or screws with deteriorated washers and replace them with new ones. If left unchecked rust can eat through the metal resulting in a hole.