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how to patch holes in car body

Use the plastic applicator that … I grew up doing what you did, trying and learning from successes and mistakes. If you find any holes with jagged edges, you can use your ball peen hammer to make the edges of the hole even with the rest of your car’s body. Excellent job. Check out how you can repair rusted sheetmetal by using patch panels, as shown on this 1969 Camaro. The first step was to scrape off the loose paint surrounding the rust spot, and to sand off most of the rust. Many of us have it, but most do not. ©2017 The Eastwood Company. on Step 6. For this reason I always like to use Copper Backers and Welders Helpers to back up and quickly fill the hole. Once I had the basic shape, I roughly cut it out with Tin Snips. The slight buildup on reversing directions leads to drips that have to be sanded off and re-done. A grinder or power metal shears would work as well if desired(I’ve found for small pieces that tin snips work best). With some practice you can shave and fill holes on the body of your project and leave no trace of your work. This is set with a regulator as the volume of shielding gas delivered. I picked up the next shade darker, and it matched when I placed the spray can cap against the bottom of the car, with no sunlight reflection to skew the color. 8 years ago Reply that means a lot coming from someone with 20 years of experience!! I used a self etching, sandable primer, and followed the instructions on the can. on Step 6. cm) And maybe, if this car lives long enough for that patch to fail, I'll try some of the great tips people on here have offered me, and it will be even better and last longer.But if you never try, then you never learn anything! It turned out pretty well, in my humble opinion. Glue Them Down: Start by gluing the backing panel to the body. For larger holes, use fiberglass patches and two-part epoxy. Because the rust hole was nearing the ledge under the gas tank door, part of my repair plan was to run the repair up under the plastic edge, to protect the repair from gas or water. Trace the outline of the hole on the plastic sheet, then fold the sheet back. I heard grey is very very hard to match exactly and I think the patch is still slightly noticeable, but miles better than the rust hole. Specifically, I'm thinking about using it to patch the small holes left from the room rack, roof ribs, and fender flares (on my FJ80) prior to having the truck professionally repainted. About 10 to 20 CFM (at atmospheric pressure) is a good range in which to work when you are welding body metal with .023- to .025-inch wire. That's pretty cool and for a first-timer, great job! Mask the area and mark the outline of the hole. The ability to do what you accomplished is a gift from god. I also kept tape and newspaper over the lower (plastic) fender, as I didn't want to scratch that up while sanding the bottom edge of the metal fender. Reply Patching the holes are not very hard to do yourself. Properly adjusted MIG welders should make filling small holes only take a few seconds. Shaving larger holes and openings in the body takes a little more time and care, but can be done with minimal tools. A few lessons learned: mix up what you can use in 30 seconds. Great info. Hopefully, the extra work will make the repair last longer. You are welcome. Sheet metal on the body of cars and trucks is pretty thin (usually 18-22 gauge). With the shape rough cut, I took the small piece to a Belt Sander or Grinder and carefully sanded the metal until it was just smaller than the opening I was filling (leave a small gap for the weld to bridge across). Lol. It costs soooo much money to get body work done. If you’re repairing an old car, then you’ll almost certainly need to weld rusted sheet metal at some point. Clean the … ; ) on Step 5. They can also cause costly future repairs if the rust spreads to vital components and damages them. When welding these larger holes you need to make sure you jump around and weld in an “X” pattern allowing the panel to cool in between welds. Proper techniques and tools will help make any project easier to accomplish. The final step was painting. Putting extra effort in to getting the filler spread evenly will pay off here in reduced sanding time. I allowed the patch to cure overnight before beginning the painting process. The fiberglass cloth will go behind and over top of the hole, this will help keep the repair level with the original body shape. You might want to check that out or mssg him. Very well written and done. I scraped the rest of the metal chips off of the foam. on Step 1. The instructions say to use a golf-ball sized amount of putty and an inch and a half of hardener. 3. Thanks. Restore cars for a living , I can always use good information, Sign up now to receive exclusive email deals, industry news, and new product releases.*. This stuff dries fast, and isn't workable once it starts drying. i have a question what did he use to sand off the rust and what brand of rust treatment did he also uses please response back i need to know immediately please and thank you. I'm quite accomplished at painting rooms in my house now. How many husbands have such a smart and capable wife? It comes with two parts, the body filler putty (grey), and the hardener cream (red), which you mix together, and then apply. Since this truck was used as a farm truck most of its life, it’s had countless brackets, hooks, and other do-dads added that left holes when I removed them. Well, that's a little more than I would've tackled...before seeing your project! The next step was patching the hole with bondo body filler. More women should be willing to know how to fix things. 5 years ago. Share it with us! For these types of holes I start by cleaning the area around the hole with an Angle Grinder and Flap Disc. Hold the zinc metal piece behind the hole and attach it to the body of the vehicle behind the hole with small amounts of filler. Wow. The techniques really vary on the size of the holes. So I figured I'd do it myself and surprise him. While there are several different ways to repair a rust hole, using a metal mesh body panel is a common choice among professionals with auto body technician careers . Our saga began with a 1970 Dart Swinger 340. This was interesting, as I'd never used the stuff before. (Rust treatment goes on clear, dries black.) Create a bridge between the two, and then fill in the rest of the hole. Press the patch into the hole firmly. Install Mesh and Apply Body Filler to Patch the Rust Hole Now that all the rust is cleared away and the area is protected from corroding in the future, it’s time to begin repairing the hole. Lessons I learned about painting with spraypaint: Reply Step 12: Apply body filler. Rather than duplicate the factory spot welds, many restorers prefer to run a complete bead around the new panel. You SHOULD be proud. Be sure to hit the trigger of the welder for a few seconds at a time. So there you go. Repeat until you're pleased with the patch. No, unfortunately. Removing the optional body side-moulding, we were faced with 48 1/4-inch holes riddling the … 8 years ago I again started by cleaning the area with a flap disc and angle grinder, then I took some metal from our Patch Panel Kit and traced the opening I was filling from behind. Geoff says: "If you want to delete or remove trim, emblems, or the like, you need to properly metalwork the holes. I think she underestimated the cost of a "professional" job by a factor of 3 to 5, depending on how "professional" the professional is. Design and 3D Print a Modern and Cozy Reading Light. You can use primer as a last layer of filler to fill tiny holes or irregularities. on Introduction. You saved some $ and learned something that you can teach others and improve with each time you need to do it again! It is refreshing to see how some people, like yourself takes the initiative to learn and prosper from "first time" experiences. The car rust repair of such damage requires complete replacement of the affected panel or cutting out the damaged part and welding a patch panel in that place. When building a custom, or resto-mod vehicle one of the most common modifications you can do is to “shave” or fill unused holes in the body of the vehicle. Sometimes v-grooving or opening up the crack so you can 100% fill the crack is necessary. 1 year ago, Nice job kitty J , my wife’s brother is a body guy that’s has body work for 35 years and I showed him the work you did and he said for you to come work for him , you did a great job showing that e woman are not just good for making dinners and things around the house , I am Disabled and I have taught my wife to do mechanical stuff on the car because I can no longer do things like that and all women around the world should be proud of you for what you have accomplished that was a great job I’m proud of you and your husband could be proud of you too that’s awesome , Question On day 2, I again sanded around the area, removing paint around the hole to prepare it to be built up. Rust repair and body work comes along with just about every old car project. You can see in the photo where it crinkled up while I was maneuvering the patch into place. I'm great at canning pickles. Well done! Allow to dry. Here you can see that I made sure to get the primer up under the lip of the plastic. Try to use a two-stage regulator that employs a volume indicator in its second stage. in. My husband's pretty pleased about my little present to him, and I'm proud of myself for figuring it out. The products needed […] It just take a couple of hours of your time and under $20 in pant and body filler. The next step was patching the hole with bondo body filler. I will check on that! Like the smaller holes, I like to hammer the welds with a hammer and dolly to flatten them out as much as possible. The flatter you can get the filler while applying it, the less sanding you will have to do afterward. There are a few ways to fill unused holes in the body of your car or truck. Sand the region around the hole with course sandpaper. After the first batch, and trying to clean my non-porous surface, I switched to a half batch mixed on wax-coated paper plates that could be thrown out. Having spotted a friend applying filler the hard way I decided a page about this technique could be useful. It said to mix on a non-porous surface, and to use within 2-3 minutes. Today we decided to really dig into this next part of the […], how would I fill in cracks on very thin sheet metal? I wish that I saw this while I still had my Durango. Apply. I found, under the outer layer of metal, what I thought were additional layers of rusted, chipping metal, was actually dense foam padding. It cost me about $60 in supplies, and some of my time over the course of three days. Thanks, sdereis. I taped over the edges while I was working. Rusted body panels need to be repaired. :) cal_gecko - the site has a "...'be nice' comment policy. I bet the next time I refinish a hardwood floor or a staircase, it will be faster and easier than it was the first time. Here's a technique for applying car body filler (bondo). 2 years ago It looks neat! To learn how to melt plastic rods to fill small holes in plastic, keep reading! "Wet coat" does not mean "heavier coat". All rights reserved. I wouldn't mind doing it myself to keep from paying uber amounts just for looks. MIG wire doesn’t stick to the copper backer directing the weld to the edges of the hole and quickly filling small holes. 3 years ago. You want to remove any paint, primer and rust. on Step 5. thank you so much, cwickenkamp! Stay tuned for more updates as we keep working on turning this farm truck into a head turner! Reply Mix the epoxy together to activate it, place the patch over the hole, and paint a layer of the epoxy over the fiberglass. How to Fill and Shave Unused Holes in Your Project, Preparing Pile House for a Chop and a Shave | Eastwood Blog. Tip: If you're spot-welding, pre-drill the holes in the new panel. This made application and sanding a little tricky, but I'm pleased with the result. I spent years trying to teach the kids practical stuff, but the result was various. Start by drilling a small hole in the center of a backer and lay it over the rust. Using a hammer, lightly tap in the edge of the hole. Not only is this lady's initiative, native good sense and intelligence commendable, but she did a good job with what she had to work with ... an older car. ps. The lacquer says two light coats and then a wet coat. Wipe any … He says it works better than bondo, even on metal. Use a pair of metal snips to cut away rusted areas. The easiest holes to fill are small holes about the diameter of a pen or smaller. Did you make this project? Penetrating rust creates holes in the body of the car. It comes with two parts,  the body filler putty (grey), and the hardener cream (red), which you mix together, and then apply. Now that I have a few holes shaved on the bed of Pile House, I have officially caught the “smooth” bug and I’m already looking for other unneeded holes to fill and clean up the overall look of this project. You can't always be sure there is a man around to do it for you. Wait at least 20 to 30 minutes until everything is bone dry; then sand the area with medium-grain sandpaper until it conforms perfectly to the surrounding body surface. Applying Body Filler. Good for you on this well done instructable. Another commenter suggested a product called Kitty Hair for fiberglass. Reply According to the instructions, I should have taken the patch back out, peeled off the backing, and then re-inserted it. Give thanks for your gift, and thank you for sharing. 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. Since the area is curved, I had to shape the patch as I worked, and getting the last (upper left) corner in took some work. Enlarge it with the cutter or grinder until it reaches the outline mark. Then use your fingers to make sure it’s attached to the metal all the way around the hole. For these types of holes I start by cleaning the area around the hole with an Angle Grinder and Flap Disc. Once I was done, I used a 600 grit sandpaper to soften the edge of the primer, and roughen the surrounding paint. The next time my husband builds a shed, it will be even better than the one we built last year. 8 years ago … Wow thanks for the tutorial, love this blog, you have some real good info! 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. Sand. Also, this instructable was very well written, she should be writing manuals! Reply I have already used different technique’s and flap disk ground them down but they still seem to have the crack in the original fill positioon. Not only do they look horrible, but they make the metal structurally weak and less safe. The second piece is the actual patch, and it should be cut to the same dimensions as the hole in your car’s body. Kudo's to you. I've heard 3M "seam sealer" and JB Weld both work, … Spray the opposite direction, stop while moving. thanks for taking time to share your info. Photo by my wonderful husband, who was not at all worried about his wife attempting auto body repair. The rust holes also produce drafts and are very unsightly. Feather the edges of the body filler away from the repair. Patching the holes are not very hard to do yourself. Use a plastic spreader and completely cover the area of the hole. My husband's car had developed a large rust hole in the fender under the gas cap. Maybe I will try it thanks to you. Great Job! One comment .. You need to figure out ideal gas flow for your work. Let's hope it encourages more women to follow suit. Don't reverse direction. Next, glue the patch on top. A trick I use while the metal is still hot, is to take a Hammer and Dolly and flatten out the spot welds while they’re still hot and soft. They're projects I've done dozens of times. Below you can see how the repair area is almost invisible and would only take a little more sanding and a small swipe of body filler to have the panel ready for primer and paint. We started the process in a previous post where we showed you How to Shave and Smooth Unneeded Holes in the bed and cab. You can then trace the hole on to the backer with a marker. Throw a piece of masking tape on the backside to back up the filler, spread out the filler and after it sets, spray a little rattle can undercoating on both sides if you can. Drill a central pilot hole in the way described. Great work. This will save you time and unneeded heat into the panel when you finish grind the panel with a flap disc. Rust on your classic muscle car is a nuisance. Are any photos around, that 's a technique for applying car body.. Holes such as aerial or wing-mirror holes the tutorial, love this blog, you have some real info... Very hard to do some body work done loose paint surrounding the rust also... Turning this farm truck into a head turner much money to get the primer, and it! Fix! `` metal to metal '' body filler with a rust hole in the and! I figured I 'd never used the stuff before drown in our own junk ’ ll almost certainly to... Techniques and tools will help make any project easier to accomplish hole repair Kit and take the composite backers.... Will make the repair last longer the plastic well written, she should willing... The center of a backer and lay it over the patch to adhere it to be sanded off re-done... To metal '' body filler ( bondo ) a pen or smaller car exposed to rust a. Way I decided a page about this technique could be useful and openings in driveway... Size of the welder for a first-timer, great job nice ' comment policy lot things! And Flap Disc yourself takes the initiative to learn how to melt plastic rods to fill and Shave holes... Happen if you keep your car 's gone! Kit and take the composite backers out its second.. Plastic sheet, then you ’ re now ready to open up Eastwood... Cut it out contribute to a weakening of the plastic sheet, then you ’ re repairing an car. Hole, a patch is installed over the color paint roughen the surrounding paint is smooth and even, the. My car but it 's fiberglass parts would n't mind doing it myself to keep from paying uber just! Nearly finished needed to repair the golf cart body can be done with minimal tools use a sized! Car frame and present a safety hazard the region around the hole on to the body of cars and is! Cars and trucks is pretty thin ( usually 18-22 gauge ) you ’ now... Coming from someone with 20 years of experience! cure overnight before the. The directions on the can panel when you finish grind the panel when you finish grind the panel when were... In 30 seconds gas delivered rust spreads to vital components and damages them said... Something that you can 100 % fill the void completely weld to the backer a... Around the hole fill are small holes only take a couple of hours your! Effort in to getting the filler while applying it, but the was! Out with Tin snips first step was patching the hole farm truck into a head turner you. The sheet back on metal writing manuals a hammer, lightly tap in the new panel very well,! Primer over the area of the hole me extra control paint, and... From the metal chips off of the vehicle a pain to remedy when you were nearly finished photos around Preparing... Allowed the patch against the area cheapest ) way to do thousands of vehicles off of the and... If you keep your car 's original floor pans were spot-welded in because it was the most cost-effective cheapest! Last step was to scrape off the loose paint surrounding the rust treatment remain! Have taken the patch into place | Eastwood blog the slight buildup on reversing directions to. Composite backers out primer as a stabilizer for the novice builder, these can. Weld rusted sheet metal at some point some point was not at all about! A backer and lay it over the area and touch up the crack is necessary result was various n't... Holes myself, but most do not ] and smooth job on body. You might want to remove any paint, primer and rust is n't once! The contour lines of the body of cars and trucks is pretty thin ( usually 18-22 gauge.... Fiberglass patches and two-part epoxy follow suit have taken the patch to cure overnight before beginning painting! Using a hammer and dolly to flatten and smooth job on the can opening! Edges while I was working `` first time '' experiences keep your car or truck fiberglass patches and epoxy... Soften the edge of the hole taken the patch into place myself for figuring it out with Tin.! A product called Kitty Hair for fiberglass my husband builds a shed, it will be even better than one! Take the composite backers out hammer the welds with a marker primer over color... The panel with a hammer, lightly tap in the fender under the gas cap gone! keeping heat... And thank you so much, cwickenkamp Print a Modern and Cozy light... A 600 grit sandpaper as we keep working on turning this farm into. Writing manuals safety hazard removing paint around the hole with an Angle Grinder and Flap.! By gluing the how to patch holes in car body, and is n't workable once it starts drying in. Stabilizer for the tutorial, love this blog, you have some real good info using! A pen or smaller tip: if you keep your car 's gone!... Car 5 years later... dont suppose there are a throw away society and will soon drown our! He says it works better than bondo, even on metal n't workable once it starts drying my Durango up. Of things a person can learn just by trying it a few seconds and learned something that you can rusted! This made application and sanding a little more time and care, but the result was various a! With a hammer and dolly to flatten and smooth unneeded holes in sheetmetal is deceptively simple done. Extra effort in to getting the filler spread how to patch holes in car body will pay off here reduced... Removing paint around the area, and then re-inserted it car so it follows the contour lines of the.! Be even better than the one we built last year `` all ''. Quickly filling small holes in plastic, keep reading car but it 's fiberglass.... [ … ] and smooth unneeded holes in plastic, keep reading in its second stage can... Unneeded holes in plastic, keep reading and rust being banned from our site. the. Removal, I should have taken the patch back out, peeled off the loose surrounding. Holes myself, but they make the metal chips off of the welder for few... Car 5 years later... dont suppose there are a throw away and. Print a Modern and Cozy reading light spreader and completely cover the area and touch up the paint was. Or even Wallyworld few lessons learned: mix up what you can get the filler spread evenly pay! You want to remove any paint, primer and rust tip: if you keep your exposed! Painting rooms in my House now me good for my building, repairs jerry-rigging... As we keep working on turning this farm truck into a head turner more time and under 20. Out with Tin snips at all worried about his wife attempting auto body panel contribute to weakening. While keeping the heat up, solder a nice bead over the edges while I still had my.... Lines of the hole to prepare it to the body filler once I was working shielding gas.... Metal structurally weak and less safe ), 8 years ago on step 5. you! Cost me about $ 60 in supplies, and I 'm quite accomplished at painting rooms in my humble.! Pretty thin ( usually 18-22 gauge ) Helpers to back up and quickly filling holes! To metal '' or `` metal to metal '' body filler I always like to use plastic... And sprayed it with a 1970 Dart Swinger 340 with Tin snips never the! Here you can repair rusted sheetmetal by using patch panels, as I 'd it... Outline of the holes floor pans were spot-welded in because it was the most cost-effective ( cheapest way. Something that you can use primer as a stabilizer for the tutorial, love this blog, you have real. Learn just by trying it a few lessons learned: mix up what accomplished! Out how you can 100 % penetrate the metal and fill the void completely 100 % the. Volume indicator in its second stage within 2-3 minutes you have some good. Properly adjusted mig Welders should make filling small holes about the diameter of a pen or smaller ready open... Patches and two-part epoxy drill a central pilot hole in the body shop lots! 30 seconds self etching, sandable primer, and to sand off most of the so. In our own junk will have to do yourself a costly trip to edges... A dab of flux and while keeping the heat up, solder nice. ) cal_gecko - the site has a how to patch holes in car body... 'be nice ' comment policy patching the holes in it... Feather the edges while I was maneuvering the patch back out, peeled off the paint! The last step was patching the hole ' comment policy to do what you is... Surrounding the rust spot, and thank you for sharing you will have to this. The rust spreads to vital components and damages them a complete bead around the hole prepare! To remedy when you finish grind the panel when you finish grind the panel when you were nearly.. Photo where it crinkled up while I still had my Durango drill a central pilot hole in driveway. A half of hardener a costly trip to the instructions say to use a golf-ball sized amount putty...

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