How To Repair Large Holes In Auto Body Side Panel

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When rust isn't caught early, it can eat all the way through the metal of your car. As long every bit these rust holes become untreated, they will go along to expand. Fixing a rust hole in your car requires first removing the rust and whatever affected metallic, and then filling the pigsty with a fibreglass body filler. From at that place, information technology's just a affair of giving the repaired area a end that you're happy with.

1
Put on work gloves and eye protection. Rust is highly probable to flake equally y'all grind information technology off of the metallic. Those flakes tin go into your eyes and wreak havoc. Yous likewise run the risk of being scratched or cutting by jagged metal while you work. Avoid both concerns by wearing piece of work gloves and middle protection.^[1]
- Goggles offer the most protection, but regular safety glasses will suffice.
- Leather work gloves will give you the most protection from scratches and cuts.
two
Remove the paint two inches (5 cm) around the rust with a drill fitted with a wire brush. The filler won't adhere to pigment, then you lot have to remove it from all around the hole. A wire brush attachment for a power drill volition brand curt piece of work of the paint on the metal and can even be used to remove some of the rust, if non all of it.^[ii]
- A flapper disc for an bending grinder will also work well for removing the paint.
- You tin buy a wire brush attachment for your drill at your local auto parts or hardware store.
- You can besides buy flapper discs for angle grinders at your local hardware store.
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3
Cutting the afflicted metallic away from the hole with tin snips or a grinder. All of the rust needs to be removed from the pigsty and the metal surrounding it. If you lot don't have a grinder or bending-grinder, you lot can use heavy duty tin can snips to cut the rust and rusting metal out of the hole. If you lot do take a grinder, use it to apace grind away all of the rust and whatever rusting yous see on the metal surrounding the pigsty by pressing the grinding wheel directly into the rusty metal until it's gone.^[iii]
- A grinder is the faster and preferred method of removing all of the rusted metal, simply snips volition work in most situations.
- You can buy an bending grinder or tin snips from your local hardware shop.
4
Care for the exposed metal with a rust inhibitor. With all the rust removed, the exposed metal that'due south left is even so susceptible to rusting. Spray the entire area liberally with the rust inhibitor to end the spread of any new rust before moving on.^[4]
- Rust inhibitor tends to dry quickly. Await a infinitesimal or two for it to dry before moving on.
- Follow the instructions on the spray can of rust inhibitor y'all choose to brand certain y'all utilise it correctly.
- Y'all can get rust inhibitor at any hardware or auto parts store.
v
Utilize a ball-peen hammer to tap the edges of the hole inward. There may be jagged edges left over from grinding or snipping away at the metal. Use the back end (rounded end) of a small brawl-peen hammer to bang any edges into the hole and then they don't interfere with applying the fibreglass mixture later.^[v]
- Tapping the edged inward will allow you to brand a flat, fifty-fifty cease in the fibreglass.
- Be careful non to paring whatever of the good metallic on the body of the car while y'all bang in the edges of the hole. Don't hit whatsoever part of the auto with the hammer except those edges.
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1
Tape a sail of wax paper over the hole using masking tape. The wax paper is going to serve equally the start of your fibreglass patch. Identify it over the pigsty so the pigsty itself is near the center of the paper. Use 1 or ii pieces of masking tape to secure the wax paper over the pigsty.^[half-dozen]
- It's best to practice this in direct sunlight or in a well-lit expanse considering yous'll demand to exist able to see the hole through the wax paper.
- Apply masking tape rather than duct or some other kind of record because it won't exit an agglutinative residue.
ii
Trace the hole with a marker on the wax paper. Use a permanent mark to trace the outline of the hole past looking at it through the newspaper itself. The outline does not accept to exist perfect only should estimate the size and shape of the hole.^[7]
- Printing the paper confronting the torso of the auto with your non-dominant hand as you trace to help you lot to see the hole better.
3
Mix the fibreglass filler mixture with the hardener with a dowel. Squeeze out or cascade some fibreglass filler onto a paper plate or piece of paper-thin, then add hardener and mix the ii together with a wooden dowel or tongue depressor. Different brands of fibreglass patch material utilize dissimilar chemical concentrations, so make sure to read the instructions carefully to know how much have the hardener to add to the filler.^[8]
- Mix the filler and hardener quickly and thoroughly. You only have about 5 minutes to apply the mixture once y'all arrive.
- The filler and hardener are usually unlike colours, so it's easy to tell if they still demand to be mixed. Keep mixing the ingredients until the mixture becomes one solid colour.
4
Lay the wax paper on the table and so you can come across the traced pigsty. Place the paper down in front end of you with the traced hole facing upward. You'll demand to be able to see the size and shape of the pigsty as you add the mixture to the paper.^[ix]
- Information technology doesn't matter which side of the wax paper you used to trace the hole (shiny or flat side) just as long as y'all can clearly see its dimensions.
5
Dab the mixture onto the drawn hole on the wax paper. Keep stirring the mixture as you scoop it upwards with your wooden dowel and apply information technology to the wax newspaper liberally in the middle of the hole y'all traced. Spread information technology effectually and so it fills the entire circle you drew.^[10]
- Keep stirring the mixture and adding it to the wax paper so it creates an even patch out of the fibreglass.
six
Go on adding the mixture until it extends .v inches (one.3 cm) beyond the pigsty. That extra area will allow the patch to bond to the metal you exposed with the wire brush that surrounded the hole. Information technology doesn't have to exist verbal, just make sure the patch extends across the outer perimeter of the hole all the way effectually.^[11]
- Proceed calculation the mixture until the patch itself is about .25 inches (0.64 cm) thick and mostly even.
- Remember to movement quickly considering the mixture is already starting to dry out.
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i
Employ the dowel to apply the mixture straight to the edges of the pigsty. This will give your patch a better run a risk at adhering to the car'due south body. Apply the fibreglass mixture lightly effectually the edges of the hole by scooping it up with the dowel and then running the dowel along the edge.^[12]
- It doesn't need to be much. Just add a thin layer of the fibreglass mixture to aid your patch stick.
2
Pick upwardly the wax paper with the mixture facing outward. Pinch the edges of the wax newspaper with the thumbs and alphabetize fingers on both hands and hold information technology up in the air then the mixture is facing the automobile and away from y'all.^[13]
- It may help to reposition your hands so one is pinching a top corner and one is pinching a bottom i.
- Be careful not to allow the paper fold then the mixture comes into contact with itself or you'll have to outset over.
3
Press the mixture directly into the hole so it'southward apartment against the vehicle. Pull the corners tight so the patch is flat as you lot first utilize information technology to the vehicle. Then press the palm of your hand firmly over the patch to adhere information technology to the vehicle.^[14]
- Press the patch into the hole firmly. And so utilise your fingers to brand sure it's fastened to the metal all the way around the hole.
- Use your fingers to flatten and smooth the patch against the area of the automobile so it follows the profile lines of the vehicle.
4
Await an hour for the mixture to dry. These fibreglass mixtures dry out very apace. On modest holes, information technology may only accept a few minutes for the mixture to dry enough to work with. Withal, it'south meliorate to exist safe than pitiful. Give the patch plenty of time to dry earlier attempting to practice whatsoever more piece of work on it.^[15]
- The patch volition dry faster with practiced airflow. Open the garage door if yous're working indoors and the conditions permits.
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1
Peel the wax paper away from the vehicle. Pinch 1 corner of the wax paper with your thumb and alphabetize finger, so peel it away from the patch slowly. If the patch appears to be disrupted by you pulling on the wax newspaper, it's not dry all the same. Give information technology another hour, then attempt to peel it off once again. Otherwise, remove the wax paper completely.^[sixteen]
- The fibreglass patch will stay in identify with the wax paper gone.
- The patch is at present secured onto the vehicle.
ii
Sand any imperfections out with 220-grit sandpaper and water. ^[17] If there are whatever imperfections in the patch, you tin can remove them by pouring water over it as you sand it with 220-grit sandpaper. Keep pouring water over the patch every bit you sand information technology until the fibreglass is equally smooth as you want it.^[18]
- Be conscientious not to press too hard into the middle of the patch every bit you lot sand or y'all may break through it.
- If you accidentally sand as well much away, you lot tin can mix more fibreglass and add it to the patch, allow it dry, and commencement sanding once more.
3
Add a spray-on primer to prevent farther rust. ^[19] One time the fibreglass patch has a nice, even finish, use an fifty-fifty coat of automotive primer from a spray can. Shake the can well, and so hold it well-nigh 12 inches (thirty cm) away and swipe the can from left to right equally yous spray it. Be certain to cover the patch and whatever exposed metallic.^[xx]
- Allow the primer dry overnight before doing any more work to information technology.
- At this bespeak, the hole is repaired and won't start rusting again.
4
Pigment the repair if yous want a professional cease. ^[21] You tin can purchase automotive paint matched exactly to your vehicle by contacting the dealership and giving them your VIN (Vehicle Identification Number). While painting a car is a hard and complex process, applying a layer of matched touch up paint to small repairs can make them pretty inconspicuous. Simply spray it on the same way you did the primer.^[22]
- Hold the can about 12 inches (xxx cm) away from the surface area you lot're painting and swipe it from left to right every bit you spray.
- For larger repairs, you should care for and paint the unabridged console of the car if yous want it to blend with the residual of the vehicle perfectly. That may exist a job for a certified body shop if you lot don't take the tools and expertise required.
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How can I get rid of rust on my machine?

Tom Eisenberg is the Owner and General Managing director of West Declension Tires & Service in Los Angeles, California, a family unit-endemic AAA-approved and certified auto shop. Tom has over 10 years of experience in the motorcar manufacture. Modernistic Tire Dealer Magazine voted his shop 1 of the Best 10 Operations in the State.

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How can recurring rust be prevented?

Tom Eisenberg is the Owner and General Manager of Due west Coast Tires & Service in Los Angeles, California, a family-owned AAA-approved and certified automobile shop. Tom has over ten years of feel in the auto manufacture. Modern Tire Dealer Mag voted his store one of the All-time x Operations in the State.

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Things You'll Need

Center protection
Work Gloves
Power drill or grinder
Wire brush drill bit
Tin snips
Fiberglass patch kit
Wax newspaper
Permanent marker
Automotive primer
220-grit sandpaper
Automotive paint
Wooden dowels or tongue depressors

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Article Summary Ten

To prepare rust holes on your car, you'll need to go rid of all the rust first. Remove all of the pigment around the hole with a wire brush zipper on your drill. You'll also demand to cutting abroad the afflicted metal with a grinder or tin can snips. One time you've cutting abroad the metal, cover the pigsty with a piece of wax paper and apply a mixture of fiberglass filler and hardener. Let the mixture dry for about an hour, then pull away the wax newspaper. You can also sand downwardly the patch with 220 grit sandpaper to remove whatever imperfections. For tips on how to preclude the spot from rusting again, keep reading!

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