How To Replace Rusted Sheet Metal

Sheet metal is a huge part of any hotrod build or autobody repair.

How to replace rusted sheet metal.

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. Once down to bare metal all the damage is revealed. If the metal around any fastener has rusted and a hole has developed repair the rusted hole before. 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. A rust hole compromises the structural integrity of the metal. If left unchecked rust can eat through the metal resulting in a hole. You can t just mask over it but have to remove it completely and replace the section with new sheet metal.

When water contacts bare metal rust forms on the surface of the metal. Use an air sander to quickly bring the rusted area down to bare metal. A 36 grit sanding disc works best. I then used the templates to trace out the patch panels on some sheet metal.

To remove rusted screws start by rapidly hitting the screw head with a hammer to break the rust seal. 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. Here is a tutorial how to video that show.

You should now have a shiny solid rust free surface. Clean the exposed metal area with a 60 or 80 grit disc. Whether you re fixing a dent rust hail etc. Repairing rust or a rust hole on metal without welding requires a material that bonds and is as strong as metal.