How to Remove Rust Holes on a Car

Rust holes are repaired with patches.

Rust holes occur in the body panels of cars after consistent exposure to moisture, water or salt water. These holes start as small holes in the paint which leads to corrosion that eats away at the metal from the edges of the hole out. To repair rust holes in a car, the corrosion must be stopped, then the hole filled. This is the only way to completely remove and repair the damage. Otherwise, the rust will continue and the hole will grow.

Things You'll Need

• Magic marker
• Metal saw
• Auto body putty
• Patching material
• Primer
• Paint

Instructions

1. Find the edges of the rust hole by carefully inspecting the entire panel front and back. Mark the ends of the hole with a black magic marker.

2. Cut out the rusted metal using a metal saw, following your marks. Inspect the edge of your cut to ensure that there are no signs of rust inside the metal beyond the edge of your cut.

3. Clean the edges all around the hole you have cut with a degreaser. Rinse thoroughly and then sand the edges with a low grit metal sandpaper.

4. Cut out a metal mesh patch slightly larger than the size of the hole you just cut in the car. Apply this to the inside of the vehicle panel, covering the hole, with a metal adhesive.

5. Apply auto body putty over the metal patch with a plastic scraper forming a substantial layer of putty at least 1/4 inch thick across the surface of the patch material. Let it dry for six to 12 hours.

6. Sand the dried putty with a low grit sand paper until it is flush with the adjoining panel material. Rinse clean with water and let dry.

7. Apply a coat of automotive primer to the bond area. Let it dry and then apply another coat of matching automotive paint to finish the panel.

References

• Car and Truckt Tips: Removing Rust Holes

Resources

• Carcraft: Filling Trim Holes