How To Repair Rust With Sheet Metal

Make sure to get as much rust off the surface at this point as possible.

How to repair rust with sheet metal.

Sand the area with a coarse grit sand paper using a circular motion. This should be the result with the bad part of the panel removed. Pull the trigger of the angle grinder and run the spinning 60 grit flapper wheel over the rusted area of the metal. Lay the removed section on a piece of fresh steel and trace the outline.

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. The complexity of welding increases as the thickness of the material decreases. The most permanent repair to a hole in sheet metal is to weld the hole shut. While sanding the rust.

If it gets dirty the weld won t turn out very strong. How to repair rust without welding. Paint brush power brush the rusted areas with the wire brush on the power drill to remove the loose rust and flakes from the sheet metal. And maybe the epoxy would result in a more rustproof seam.

Wipe the wire clean with a dry cloth. Make sure not to cut through the underlying metal. 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. Attach a 60 grit flapper wheel to a 4 5 inch angle grinder and put on your safety glasses.

Use aws er70s 6 steel wires for a higher quality. The first thing to do is carefully cut away the rusted out area.