how to repair large rust holes in car body

Repairing a Rust Hole in a Car

• Step 1: Scrape and Sand. The first step was to scrape off the loose paint surrounding the rust spot, and to sand off...
• Step 2: Building Up (part 1). At this point, I used a metal mesh body patch (bondo brand) to fill the hole, replace the...
• Step 3: Building Up (part 2). The next step was patching the hole with bondo body filler. This was...

Full Answer

How do I stop rust from spreading on my car?

Surface rust

• The first step is to prep your car. Cover the car with the plastic sheet to protect it from the fine dust that will blow momentarily. ...
• Next, don your gear. ...
• Commence sanding. ...
• Once the shiny metal has been exposed, clean the area again with the wax and grease remover. ...
• Using rust prevention paint is recommended as you will not need a separate primer. ...

What is the best rust treatment for cars?

Verdict

• Jenolite Rust Converter spray
• Bilt-Hamber Hydrate-80
• Hammerite Kurust

How to remove small rust spots in a car?

Why These Tiny Rust Spots Create on Your Car?

1. Identify the Spots. First thing first, you need to know and locate the areas where these rusts had taken place. ...
2. Wash the Affected Area. The rust affected area need to be washed at this stage. ...
3. Prepare the Area for Painting. ...
4. Learn the Color label of Your Car. ...

How to repair rust on your car without welding?

• How These Adhesives Work
• How They Can Save You Money
• How You Can Use Them Yourself

How do you fix a big rust hole on a car?

0:197:00How to Repair Rust Holes on Your Car Without Welding - YouTubeYouTubeStart of suggested clipEnd of suggested clipThis one area though is just a big giant rust hole like you can just pull this stuff off it'sMoreThis one area though is just a big giant rust hole like you can just pull this stuff off it's literally falling off so we're gonna you know do the old bondo repaint it prime it all that good stuff.

How do you Bondo a large rust hole?

0:502:07How To Repair A Rust Out with Bondo® Filler - YouTubeYouTubeStart of suggested clipEnd of suggested clipStart with a thin skimp coat and then apply enough filler. So that it's slightly higher than theMoreStart with a thin skimp coat and then apply enough filler. So that it's slightly higher than the surrounding. Area. Let the filler dry. Completely shape and sand the repair with 40 grit sandpaper.

How do you fix a big rust hole without welding?

0:1417:27DIY Repair Rust Holes with Basic Tools and NO Welding! - YouTubeYouTubeStart of suggested clipEnd of suggested clipRight here at home and we're going to show you today how to fix little rust holes without doing anyMoreRight here at home and we're going to show you today how to fix little rust holes without doing any welding. And just using some reinforced body filler.

Can rust holes be repaired?

0:4634:08How to PROPERLY Repair a Rust Hole in your Car or Truck (DIY for ...YouTubeStart of suggested clipEnd of suggested clipBefore we do that we need to fix some odds and ends to make this safe and reliable for double theMoreBefore we do that we need to fix some odds and ends to make this safe and reliable for double the horsepower also just for driving around in general we need to fix that rust hole and in order to fix

Will rust come through Bondo?

To Bondo or Not to Bondo Minor surface rust can often be sanded and painted, but major rust pitting and holes may require a little more effort and material — specifically, Bondo or some other quality body filler. However, Bondo shouldn't be used on every kind of rust hole.

How can I fill a hole in my car without welding?

The two usual non-weld hole fixing options are epoxy and tape. These DIY techniques are efficient when fixing a small hole instead of a considerable tear. Tape merchandise and specialty epoxy are intended to patch metal and steel.

Does JB Weld work on rust?

5:035:46Using JB Weld to Fix Rust Holes? - YouTubeYouTubeStart of suggested clipEnd of suggested clipThis is just so my camera can focus anyway this is the final result I really can't think of a reasonMoreThis is just so my camera can focus anyway this is the final result I really can't think of a reason why jb weld could not be a viable option for rust repair.

Will epoxy stick to rusted metal?

The epoxy resin provides excellent adhesion so they bind the rust particles together and bond it to the substrate.

How do you fix badly rusted metal?

For heavy rust If the area is heavily rusted and pitted and wire brushing by hand is ineffective, use a drill with a wire wheel (Photo 2) and a primer that adheres to rusted surfaces, such as Krylon Rust Tough or Rust-Oleum. Grind down heavily rusted metal spots faster with a wire wheel and a drill or angle grinder.

How much does it cost to fix rust holes on a car?

The cost would be per area, so if you had two or three spots that were under three inches, it would be between $50-$150 for each one. Often, you can repair these minor rust spots on your own if you're so inclined....Cost to Fix Rust on a Car.Minor Rust Repairs$20 - $150Major Rust Repairs$400 - $2,500+1 more row

Is it worth fixing rust on a car?

In the majority of these situations where important equipment necessary for the automobile's functioning is impacted, repairing rust is not worth it due to the danger of driving a vehicle with weakened structures.

How do you fix rust holes?

9 Steps to Follow When Fixing Holes Using Fiberglass and Metal MeshRemove the Rust Around the Hole by Sanding It. ... Cut Around the Damaged Spot Slightly. ... Fill the Hole Using Metal Sheets. ... Add Bondo Glass Stratum. ... Sand the Spot. ... Utilize the Bondo Body Filler That's Within the Accepted Range. ... Use Automobile Primer. ... Paint the Spot.More items...•

How thick can Bondo be applied?

about a 1/4”There is no minimum thickness for Bondo, but there is absolutely a maximum. You do not want to apply body filler to anything that is thicker than about a 1/4”. That does not mean it can't be done, but the repair will not last as long. Eventually the filler will shrink and possibly crack, or even pop off!

Can you use Bondo to fill a hole?

0:155:25How to Use Bondo to Fill Holes in Wood - YouTubeYouTubeStart of suggested clipEnd of suggested clipIf you are filling a hole in wood and then you're gonna stain over the top of it as bondo doesn'tMoreIf you are filling a hole in wood and then you're gonna stain over the top of it as bondo doesn't stink but if it's a painted surface it works great so let's get started.

Can you fix rust holes with fiberglass?

Fiberglass and metal mesh can be used to fix rust holes without welding. Before you begin the procedure, make sure that you have all the things you need.

Is Bondo waterproof?

Bondo Fiberglass Resins and Repair Kits are 100 percent waterproof. Because they do not shrink, they are excellent sealers. Bondo Fiberglass Resin is sandable in less than 2 hours, is compatible with all paints, and creates a strong and long-lasting bond.

Step 1: Scrape and Sand

The first step was to scrape off the loose paint surrounding the rust spot, and to sand off most of the rust. I found, under the outer layer of metal, what I thought were additional layers of rusted, chipping metal, was actually dense foam padding. I scraped the rest of the metal chips off of the foam.

Step 2: Building Up (part 1)

At this point, I used a metal mesh body patch (bondo brand) to fill the hole, replace the missing metal, and give the bondo a place to adhere to. Using regular scissors, I cut the mesh to approximately the right shape, and then began fitting it into the hole between the metal and the foam.

Step 3: Building Up (part 2)

The next step was patching the hole with bondo body filler. This was interesting, as I'd never used the stuff before. It comes with two parts, the body filler putty (grey), and the hardener cream (red), which you mix together, and then apply. The instructions say to use a golf-ball sized amount of putty and an inch and a half of hardener.

Step 4: Primer

The next step was to apply a primer over the patch. I used a self etching, sandable primer, and followed the instructions on the can. I taped over the edges while I was working. Once I was done, I used a 600 grit sandpaper to soften the edge of the primer, and roughen the surrounding paint. That's me sanding.

Step 5

The final step was painting. The first color I used wasn't right.

Step 6: Final Result

So there you go. My first attempt at auto body repair. It turned out pretty well, in my humble opinion. I learned a lot. It cost me about $60 in supplies, and some of my time over the course of three days. My husband's pretty pleased about my little present to him, and I'm proud of myself for figuring it out.

How to bond rust holes?

To get started, the body filler needs something to stick to. Rough-sanded bare metal is best, but primed metal will do. A rust converter should be used to prepare rust-pitted surfaces for body filler. Rust converter stops the oxidation process that creates rust and prevents the rust from spreading.

What to use to fill rusty bondo?

Fiberglass sheets, metal mesh or fiberglass screen can be used. Once you have a good surface to work with, mix body filler with a spatula or plastic scraper on a piece of cardboard.

What is Bondo rust?

While “Bondo” is the name of a 3M product, it has also become a generic term for plastic body filler, and several companies make similar stuff.

How long does it take to sand a car body?

After 15 to 20 minutes, use coarse sandpaper (30 to 60 grit) to shape the repair and feather it to the surrounding body surface. After another 30 to 40 minutes, the surface should be ready for final sanding with 180 to 300 grit paper. After cleaning the dust from the surface, you’re ready to prime and paint.

Can you use bondo on rust holes?

However, Bondo shouldn’t be used on every kind of rust hole.

Is rust a fact?

Rust is simply a fact of life. It tends to be a constant issue close to the shore, in humid areas and in the salt belt. Even a chip from a stone can give rust a foothold on your car and lead to cosmetic or structural damage.

Can you rust a car?

There are some parts of your vehicle that may never rust, but other parts might seem like they could turn to dust right before your eyes without proper attention. Fortunately, if you catch the rust in time, you can prevent unsightly body damage or unsafe structural problems.

What is stitch method welding?

Technique is really the biggest key to a quality job. When welding a panel, especially a long panel like a quarter, using the stitch method will reduce warpage. Welding creates a lot of heat and the sheet metal will twist and band away from the heat.

What year was the rusty trunk lid on a Buick GS convertible?

To demonstrate this process, we cut out and repaired some rust bubbles in the trunk lid of a 1971 Buick GS convertible. This is the kind of rust you find under those little bubbles in the paint. We started by stripping the trunk of paint.

What is the best way to protect sheet metal from rust?

Another good idea when replacing any type of sheet metal is using weld-through primer. 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.

Why do you need a cut off wheel?

There are a few tools that take a lot of the pain out of this type of procedure. You need a cut-off wheel to remove the offending material in a clean manner. Usually there is something behind the rusted area, so you need to be careful not to cut through it. The cut-off wheel gives you the control.

Is it hard to weld rust on a car?

Take your time and practice before you actually weld on your car. Rust repair is not that hard, but it is really easy to make a bigger problem if you get ahead of yourself and bite off more than your skills can handle. The key here is patience and when in doubt, seek professional help.

Who is Jefferson Bryant?

A life-long gearhead, Jefferson Bryant spends more time in the shop than anywhere else. His career began in the car audio industry as a shop manager, eventually working his way into a position at Rockford Fosgate as a product designer. In 2003, he began writing tech articles for magazines, and has been working as an automotive journalist ever since. His work has been featured in Car Craft, Hot Rod, Rod & Custom, Truckin’, Mopar Muscle, and many more. Jefferson has also written 4 books and produced countless videos. Jefferson operates Red Dirt Rodz, his personal garage studio, where all of his magazine articles and tech videos are produced.