Things You'll Need:
- Air or electric sander, Die grinder, sand paper, fiberglass patching or bondo whole filler.
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Step 1
Cut out all large sections and replace with new metal. Using rivets to attach new metal.Removing rust can be challenging. What may appear as surface rust may go all the way through. Rather it is on the surface or runs through out the panel, it is imperative to sand or cut it all out or your labor will be in vein. Surface rust can be sanded down to clean shiny metal. Most people would tell you this is where you start your fiberglass patching. I personally think it is more effective to spray this clean surface with a rust prohibiting primer. Large sections of rust that turn into big holes should be replaced with metal. Some medium size wholes can be filled with bondo hole filler.
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Step 2
This surface rust is a simple task compared to replacing whole panels.Prime all fresh metal with a rust prohibiting primer. Patching surface wholes are relatively easy, you apply the fiberglass patching much like that of a drywall patch, using a plastic knife. When mixing bondo, it comes in two parts a filler and a activator. The more red or activator you use the hotter it is. The hotter it is the faster it will harden.
Medium sized wholes can usually be backed with cardboard until you have created a surface to work with. Several stages of patching and sanding will be necessary to achieve a finished look much like that of a drywall repair. Contours surrounding your wheel wells can be challenging to reform, but not impossible. Sanding with your contours will generally help this process. Reforming a contour in your vehicle takes more patching and sanding then any other surface. -
Step 3
This is a waste of your time buy a new vehicle.When you are satisfied with your patch work it is time to apply some protective coatings. Some would say this is over protective but I would rather not see the rust again when I complete this task. I put on two coats of rust prohibiting primer letting each coat dry thoroughly. I then sand smooth and apply one more coat of primer. Picking colors for top coats can be challenging, but as long as you use a paint that is a rust prohibitor life is good. Sometimes you can get lucky and match these colors up at a hardware store like I have. Harder colors to find can be matched up at a dealership. Apply your first top coat. Allow it to dry thoroughly. Apply two more top coats. wala rust free.
