how to repair rust with bondo

by Dr. Chadrick Wolff II Published 3 years ago Updated 2 years ago

How to Use Bondo for Rust Repair.

Step 1 - Locate Major Rust Deterioration. Some places on your vehicle's surface that are rusted completely through the surface will be easy to spot.
Step 2 - Clean Off Rust, Dirt, Paint, and Debris.
Step 3 - Apply Fiberglass and Epoxy.
Step 4 - Apply Bondo.
Step 5 - Smooth and Paint Your Surface.

Part of a video titled How To Repair A Rust Out with Bondo® Filler - YouTube

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Start 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.

Full Answer

Is there any way to remove Bondo?

Manufacturers have the best guidelines for specific stains. ...
Before you try any specific method, try to find the most inconspicuous area of your driveway to test the cleaning agent’s end result.
Always read the instructions on cleaning materials. ...
Thoroughly rinse areas after applying materials to paver stains. ...

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What are tips for repairing a car with Bondo?

Same-Day Repairs with Bondo

Formulated to be non-shrinking and water resistant for permanent repairs
Easy to use – cures to light gray color
Sandable in 15 minutes and paintable in 25 minutes

How to fix Bondo cracks?

5 tips for avoiding Bondo repair disaster

Tools and supplies
Prepare for the worst. Find out what’s going on under the paint. ...
Sir Mix-a-lot. Gather up the Bondo, spreaders, putty knife, mixing board, the Surform or rasp, and acetone for clean up.
Skim and carve. The curing process starts immediately, so load up the spreader and get to work. ...
Cut and sand. ...
Do it all again. ...

How to repair a hole in a car with Bondo?

How to Repair a Hole in a Car with Bondo Remove any metal that is not solid from around the area of the hole that is to be repaired. Use coarse-grit sandpaper to remove any paint and primer for a distance of 3 to 4 inches in all directions away from the hole. Use nylon window screen to fill in behind the hole and create a backer to hold the auto body filler.

Can you Bondo over rust?

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 do you fill big holes in rust?

0:297:00How to Repair Rust Holes on Your Car Without Welding - YouTubeYouTubeStart of suggested clipEnd of suggested clipHand you could use things like orbital sanders we're gonna be doing a little bit of both um then iMoreHand you could use things like orbital sanders we're gonna be doing a little bit of both um then i also got a rust remover attachment for my drill for like five bucks. So that'll work really.

What is the best body filler for rust?

Permatex 25909 Liquid Metal Filler The trusted brand Permatex is popular for repairing cracks or any leaks. This filler is very adaptable for application. It comes in a tube, making an effortless use every time. Apply the product straight from the tube, then wait for 3 to 4 hours and repeat with more layers if needed.

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.

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!

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.

Is there anything better than Bondo?

Permatex 25909 Liquid Metal Filler Unlike the Bondo filler, the Permatex product is ready to use, it does not need any mixing. This filler is compatible for many materials, but only comes in a small tube. Due to this, it is designed for small areas of damage to be repaired (such as cracks and holes).

Does Bondo stick to metal?

Any galvanized metal repair requires Bondo Ultimate. Not only does it adhere to galvanized metals, but it is easy to mix, easy to apply, and provides for clog-free sanding. Many repair products do not properly adhere to galvanized metal.

What is the difference between body filler and Bondo?

0:191:21Types of Bondo® Filler - YouTubeYouTubeStart of suggested clipEnd of suggested clipThe can just to the right is bondo professional gold body filler. It's ideal for cars 1998 or newerMoreThe can just to the right is bondo professional gold body filler. It's ideal for cars 1998 or newer because it has quicker adhesion galvanized coated metals.

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.

Do it yourself rust repair?

0:2815:03How to Repair Rust on Your Car Without Welding. Rust RemovalYouTubeStart of suggested clipEnd of suggested clipSo roast repair takes four easy steps one remove the rust juice and sandpaper. Two fill the areaMoreSo roast repair takes four easy steps one remove the rust juice and sandpaper. Two fill the area with body filler tree sand down the body filler to suit the body of your.

Will JB Weld stick rust?

0:035:46Using JB Weld to Fix Rust Holes? - YouTubeYouTubeStart of suggested clipEnd of suggested clipIt right in there around to make sure that my patch is going to stick to that JV Weldon. And jb weldMoreIt right in there around to make sure that my patch is going to stick to that JV Weldon. And jb weld sticks very well to freshly ground metal.

How do you fix rust spots?

How do you fix major rust on a car?

0:4634:08How to PROPERLY Repair a Rust Hole in your Car or Truck (DIY for ...YouTubeStart of suggested clipEnd of suggested clipWe have a drill. And the reason why we have a drills because we're gonna be using a sheet metalMoreWe have a drill. And the reason why we have a drills because we're gonna be using a sheet metal nibbler. This is really helpful for cutting sheet metal.

How do you fix a rust hole in a trunk?

4:0710:02NO MORE RUST HOLES IN THE PRELUDE TRUNK! (POR-15 x ...YouTubeStart of suggested clipEnd of suggested clipCloth. So i have a bunch of this here i'm going to cut a bunch of like smaller strands up so thatMoreCloth. So i have a bunch of this here i'm going to cut a bunch of like smaller strands up so that way they're ready to go to fill these holes that way once i mix the por-15.

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

0:0010:07Repair Rust Holes in your car. How to weld. - YouTubeYouTubeStart of suggested clipEnd of suggested clipYou can get for the grind or - there's a wire brush head especially for removing rust on your carMoreYou can get for the grind or - there's a wire brush head especially for removing rust on your car actually quite good but you can also use a flap disc as well which I've used in the past.

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.

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 is a bondo for car repair?

Body repair is often considered one of the most delicate and complicated car repairs, but learning how to Bondo rust holes is luckily quite simple. 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. The putty can be useful for filling rust holes in ...

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.

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.

Can you use bondo on rust holes?

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

What to use for bondo body filler?

To get started, the body filler needs something to stick to. Raw, unpainted metal is preferred. Primed metal will work. A rust converter should be used to prepare rust-pitted surfaces for body filler. Rust The rust converter stops the oxidation process which creates rust, and prevents the spread of rust. If rust has thinned or eaten through the panel, then the Bondo needs a backup. You can use fiberglass sheets, metal mesh, or fiberglass screen.

How long does it take to sand plastic body filler?

Can a chip from a stone cause rust?

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. Body repair is often considered one of the most delicate and complicated car repairs, but learning how to Bondo rust holes is luckily quite simple.

Can you bondo a rust hole?

However, whether or not you can Bondo a rust hole will depend on the location and severity of the rust.

What is bondo used for?

Bondo is a compound that is mainly used in the automotive industry for repairing dents, dings, or large scratches in metal. Bondo is also used to repair wood, drywall, concrete, brick, fiberglass, etc. When I was giving my wheelbarrow an update, I noticed a hole in the edge where the rust has eaten the metal away and I used Bondo to repair it.

How to mix hardener and compound?

Apply a bead of the hardener to the compound in the tray, and stir to mix the compound and the hardener.

How to sand Bondo Gold?

Power sanders are OK to break the surface and knock down any high spots, but hand sanding with the body contour is the best way forward. Cut in with heavier grit sandpaper and work out to about 80 grit to leave a tooth for the following skim coats. Make long sweeps for sanding over the repair. Run your hand over the repair and feel for depressions or high spots; anything you can feel as wavy will translate through the paint. The lightweight Bondo Gold is far easier to sand than the heavier type, so consider using the good stuff on the way out. Use a tack cloth to remove any dust between coats.

What is bondo resin?

The miraculous blend of polyester resins and cream hardener known as Bondo can make wavy panels straight and door dings disappear. It can hide a welding seam in seconds; but Bondo in the hands of those with calamitous intentions can result in a restoration nightmare.

What to use to clean up a mixing board?

Gather up the Bondo, spreaders, putty knife, mixing board, the Surform or rasp, and acetone for clean up. A piece of scrap steel works excellent as a mixing board, but don’t use anything porous or absorbent. Disposable gloves are highly recommended.

What determines the cure time of a bandaid?

Hardener and ambient temperature determine cure time. Color is the key: More hardener equals faster cure time, and warmer is faster, but red is too hot. Shoot for that Band-Aid color to prevent a Band-Aid fix.

Do not stir putty?

Fold—but do not stir—the mixture together with the putty knife until the color is uniform. (Stirring introduces unwanted air into the mix.)

Is Bondo a trademark?

A brief qualification: Bondo is a registered trademark of 3M and just one of the myriad brands and types of polyester body fillers. And as much as we appreciate Evercoat Tiger Hair for its tenacious blend of fiberglass strands and super tough resins, one can of regular weight Bondo and one can of lightweight Bondo Gold were used in this five-part journey from rust to repair.