How To Replace Rusted Sheet Metal

How to repair rusted metal without welding.

How to replace rusted sheet metal.

Remove any rusted screws or screws with deteriorated washers and replace them with new ones. Sheet metal is a huge part of any hotrod build or autobody repair. A 36 grit sanding disc works best. If left unchecked rust can eat through the metal resulting in a hole.

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. You can t just mask over it but have to remove it completely and replace the section with new sheet metal. Repairing rust or a rust hole on metal without welding requires a material that bonds and is as strong as metal. Here is a tutorial how to video that show.

Whether you re fixing a dent rust hail etc. Clean the exposed metal area with a 60 or 80 grit disc. If the metal around any fastener has rusted and a hole has developed repair the rusted hole before. Sand beyond the rusted area an inch or so.

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. I then used the templates to trace out the patch panels on some sheet metal. A rust hole compromises the structural integrity of the metal. Then spray a rust penetrant onto the screw and leave it for about 15 minutes.

You should now have a shiny solid rust free surface. 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. Once the penetrant has had a chance to soak in give the screw a few more hits with your hammer to loosen the rust further and try to unscrew it. When water contacts bare metal rust forms on the surface of the metal.