Things You'll Need:
- Tape Tarp Sander Grinding wheel Sanding wheel Sand paper (120 grit) Metal sand paper Evapo-Rust Bondo Wire mesh Primer Paint Paint sprayer
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Step 1
Determine the size of the hole. While it is possible to patch small holes with fillers, larger holes usually require the replacement of the affected areas. If the hole is more than a few inches in diameter, consider replacing the panel.
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Step 2
Cover everything but your work area with painter's tape that will not harm your car's finish and a cloth or paper tarp.
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Step 3
Grind around the hole with a sanding wheel, in a circular motion to start the process. Your first effort will be to remove large patches of rust and decaying metal. It is important not to apply too much pressure and to grind in intervals of a few seconds at a time.
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Step 4
Use a grinding wheel to fully remove any remaining rust and to smooth the surrounding area down to bare metal.
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Step 5
Apply Evapo-Rust, available at hardware and auto body stores, to the back of the hole and the surrounding metal. It is important to work on a rust-free surface and this product will eliminate what you were unable to sand off. The area around and behind the hole must be rust free or the oxidation that caused the hole initially will just continue to eat away in spite of your patch.
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Step 6
Use Bondo, a fiberglass filler also available at auto body stores, to fill the hole. It can be used on its own, but if the hole is too large, work a small piece of wire mesh behind the hole and then apply the Bondo. Allow to fully dry.
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Step 7
Sand the area by hand and then completely clean the area and dry.
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Step 8
Prime, dry, then wet sand the area. Dry fully.
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Step 9
Spray paint the area with the manufacturer's recommended color. If you cannot match the color on your own, you can contact a dealer with the make, model and vehicle identification number, to order the exact paint.
Comments
dja21149 said
on 7/15/2009 The wire mesh for larger holes is a great idea, thanks