How to Patch Rust Holes

Rusted out metal usually happens with very old metals like in classic cars. Certain metals cannot be replaced after rust appears. However, if the metal is steel like in old cars, it can be replaced with some effort. This project is difficult and time consuming, so only attempt it if you really need the rusty metal to be replaced.

Things You'll Need

• Metal-to-metal filer
• Marker pen
• Media blaster
• Air tool with cut off wheels
• Metal scraper
• Replacement metal (how much and what kind will depend on the metal you are replacing)
• Flanging pliers
• Metal chisel
• Electric drill
• Electric sander
• Panel welding clamps
• Welder
• Cleco fasteners

Instructions

1. Decide how much metal you need to replace the old. For some rusted metals, such as classic cars, metal replacement kits are sold that come with metal already in the shape of the original metal. If possible, it is a good idea to purchase these kits as the project will go a lot faster and easier.

2. Using a marker, outline the area of metal that needs to be cut away. Use a cut off wheel to carefully cut away the old metal. Cut only the rusty parts, leaving any “well” metal. If a good metal piece is below a rusted area, you may need to install a brace to keep the good pieces of metal together. Use a sand blaster to blow away all of the rust.

3. Drill holes every 1 ½ inches along the good metal part where you will be attaching the new metal. Using the flanging pliers, flange the patch metal to the drilled holes. Weld along the flanged seam to attach the metal. Drill another set of holes at the bottom part of where the metal will attach.

4. Clamp the patch to the old metal with the cleco fasteners. Drill through the patch in the same places that you drilled through for the bottom piece of good metal. Weld the patch metal to the old metal along the drill holes. If there is more rust, cut away and repeat the whole process until all the rust is gone. Weld in beads of metal rather than in one long string.

5. Media blast the whole area to smooth and clean the metal. Coat with a metal-to-metal filer to smooth the whole area. Once this is done you can move on to painting or whatever else you need done.

Tips & Warnings

• Never weld without wearing the proper safety equipment.