How To Replace Rusted Sheet Metal

If left unchecked rust can eat through the metal resulting in a hole.

How to replace rusted sheet metal.

When water contacts bare metal rust forms on the surface of the metal. Then spray a rust penetrant onto the screw and leave it for about 15 minutes. To remove rusted screws start by rapidly hitting the screw head with a hammer to break the rust seal. Whether you re fixing a dent rust hail etc.

Clean the exposed metal area with a 60 or 80 grit disc. You can t just mask over it but have to remove it completely and replace the section with new sheet metal. Remove any rusted screws or screws with deteriorated washers and replace them with new ones. 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.

You should now have a shiny solid rust free surface. Use an air sander to quickly bring the rusted area down to bare 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. 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. Sand beyond the rusted area an inch or so. A 36 grit sanding disc works best. If the metal around any fastener has rusted and a hole has developed repair the rusted hole before.

How to repair rusted metal without welding. Sheet metal is a huge part of any hotrod build or autobody repair. A rust hole compromises the structural integrity of the metal. Repairing rust or a rust hole on metal without welding requires a material that bonds and is as strong as metal.