The complexity of welding increases as the thickness of the material decreases.
Rust hole repair sheet metal.
All of the rust must go.
Rust on your classic muscle car is a nuisance.
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We have a huge selection of high quality rust repair and auto body panels including rockers cab corners wheel arches fenders and more.
And butt up to the edges of the hole.
This setup removes the remaining rust and would allow us to cut the hole to an easily patchable size and shape.
A plasma cutter reciprocating saw or die grinder can also be used for this step.
Check out how you can repair rusted sheetmetal by using patch panels as shown on this 1969 camaro.
Then go back toward the center of the hole scrubbing with heavy pressure to eliminate the rust.
The welding process actually adds new steel to the thin steel and can result in a repaired spot that is stronger than the original metal.
Weld the most permanent repair to a hole in sheet metal is to weld the hole shut.
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A rust hole compromises the structural integrity of the metal.
Two part epoxies are designed for this purpose and when applied to a clean surface the final repair will be undetectable after painting.
Welding in patch panels with a flux core welder without a gas envelope is an exercise in burn through and swearing so glue it was.
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Another good idea when replacing any type of sheet metal is using weld through primer.
The first step was to cut out the rust.
Keep sanding until you re able to see bare metal.
And maybe the epoxy would result in a more rustproof seam.
Repairing rust or a rust hole on metal without welding requires a material that bonds and is as strong as metal.
Universal sheetmetal repair panels available at low prices.
Easy to do and really strong.