Patching Rust Holes Sheet Metal

Have you ever welded something so thin and worn out that all you do is blow holes in it.

Patching rust holes sheet metal.

This high zinc paint helps protect the backside of the sheet metal from rusting a very important step in the restoration process this is something most people forget and they end up with rust bubble just a few years down the road. Switch to 120 grit sandpaper to feather the edges of the repair area. All of the rust needs to be removed from the hole and the metal surrounding it. If you don t have a grinder or angle grinder you can use heavy duty tin snips to cut the rust and rusting metal out of the hole.

I used a piece of pvc pipe a vice mount miniature metal break and body hammer kit. Also once a year or so when you have it really clean underneath get under there and spray any bare metal spots with spray paint. I then used the templates to trace out the patch panels on some sheet metal. Get all of the grass out of the mower deck before storing it and don t use sharp tools to clean the underside of the deck.

I found under the outer layer of metal what i thought were additional layers of rusted chipping metal was actually dense foam padding. Then spread the patch out so it s flat against the remaining metal. Then enlarge the sanded area so you ll have space to feather the edges. Another good idea when replacing any type of sheet metal is using weld through primer.

Reach underneath the metal if you re able to or push the patch through the hole. The patch should completely cover the hole. 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. Insert the metal patch behind the hole.

Sand through the rust spots down to bare metal. The complexity of welding increases as the thickness of the material decreases. Did you want to learn how to work around that and deliver a solid re. I scraped the rest of the metal chips off of the foam.

Screwdrivers putty knives etc this just scratches the paint and allows more rust to form. Complete the feathering with 220 grit. Cut the affected metal away from the hole with tin snips or a grinder. Keep it stuck in place by spreading a little bit of the body filler around its edges.