How To Replace Rusted Sheet Metal

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.

How to replace rusted sheet metal.

Repairing rust or a rust hole on metal without welding requires a material that bonds and is as strong as metal. A rust hole compromises the structural integrity of the metal. You should now have a shiny solid rust free surface. 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. I then used the templates to trace out the patch panels on some sheet metal. Clean the exposed metal area with a 60 or 80 grit disc. If left unchecked rust can eat through the metal resulting in a hole.

Whether you re fixing a dent rust hail etc. A 36 grit sanding disc works best. Sand beyond the rusted area an inch or so. 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.

To remove rusted screws start by rapidly hitting the screw head with a hammer to break the rust seal. Once down to bare metal all the damage is revealed. 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. Here is a tutorial how to video that show.

How to repair rusted metal without welding. 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. If the metal around any fastener has rusted and a hole has developed repair the rusted hole before.