that means a lot coming from someone with 20 years of experience!! You can see in the photo where it crinkled up while I was maneuvering the patch into place. Next, glue the patch on top. A heavy coat results in bubbles. Which is a pain to remedy when you were nearly finished. We started the process in a previous post where we showed you How to Shave and Smooth Unneeded Holes in the bed and cab. It just take a couple of hours of your time and under $20 in pant and body filler. You saved some $ and learned something that you can teach others and improve with each time you need to do it again! While I was waiting on metal to finish the Custom Running Board Build on Project Pile House, I decided to start shaving some of the unused holes in the bed of the truck. Today we decided to really dig into this next part of the […], how would I fill in cracks on very thin sheet metal? With some practice you can shave and fill holes on the body of your project and leave no trace of your work. The easiest holes to fill are small holes about the diameter of a pen or smaller. Sand the region around the hole with course sandpaper. Putting extra effort in to getting the filler spread evenly will pay off here in reduced sanding time. 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. So you won’t have much forgiveness if you try to pile weld in the hole and you can end up with a bigger hole than you started with! It comes with two parts, the body filler putty (grey), and the hardener cream (red), which you mix together, and then apply. According to the instructions, I should have taken the patch back out, peeled off the backing, and then re-inserted it. Repeat until you're pleased with the patch. 3. A few lessons learned: mix up what you can use in 30 seconds. Great work. I found, under the outer layer of metal, what I thought were additional layers of rusted, chipping metal, was actually dense foam padding. You need to figure out ideal gas flow for your work. Kudo's to you. Glue Them Down: Start by gluing the backing panel to the body. I've heard 3M "seam sealer" and JB Weld both work, … Be sure to hit the trigger of the welder for a few seconds at a time. (This is not recommended for restorations, only a quick fix!) Tip: If you're spot-welding, pre-drill the holes in the new panel. Rust holes in an auto body panel contribute to a weakening of the car frame and present a safety hazard. Reply It needed to be fixed before the winter, and my husband hadn't had the free time to repair it himself; and I didn't want to pay the $150-200 to have it done by a body shop. I wish that I saw this while I still had my Durango. on Introduction. All rights reserved. Create a bridge between the two, and then fill in the rest of the hole. Step 7: Mix the Filler Check the manufacturer’s recommendations to ensure that you mix … I wanted to fix the small rust holes myself, but didn't know how. 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. on Step 6. I spent years trying to teach the kids practical stuff, but the result was various. 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.*. It comes with two parts, the body filler putty (grey), and the hardener cream (red), which you mix together, and then apply. 2. He says it works better than bondo, even on metal. Rust on your classic muscle car is a nuisance. The easiest holes to fill are small holes about the diameter of a pen or smaller. I grew up doing what you did, trying and learning from successes and mistakes. Shaving larger holes and openings in the body takes a little more time and care, but can be done with minimal tools. When it’s dry, sand the epoxy until it’s smooth. ps. More women should be willing to know how to fix things. Also, this instructable was very well written, she should be writing manuals! The products needed […] Then press the palm of your hand firmly over the patch to adhere it to the vehicle. I would LOVE to see this car 5 years later... dont suppose there are any photos around? Use a pair of metal snips to cut away rusted areas. This stuff dries fast, and isn't workable once it starts drying. Use your fingers to flatten and smooth the patch against the area of the car so it follows the contour lines of the vehicle. How many husbands have such a smart and capable wife? 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. Apply body filler with a flexible, flat spreader, pressing it into the rust holes. ©2017 The Eastwood Company. To learn how to melt plastic rods to fill small holes in plastic, keep reading! When everything is smooth and even, prime the area and touch up the paint. 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. Very well written and done. Wow thanks for the tutorial, love this blog, you have some real good info! You’re now ready to open up your Eastwood No-Weld Hole Repair Kit and take the composite backers out. How to Fill and Shave Unused Holes in Your Project, Preparing Pile House for a Chop and a Shave | Eastwood Blog. 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. on Step 5. 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. I wouldn't mind doing it myself to keep from paying uber amounts just for looks. It was just starting to show a tiny bit of bubbling at one edge of the patch about a year ago, and I was thinking about reworking it, when a deer took out the entire car. 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. Thanks, sdereis. You can use primer as a last layer of filler to fill tiny holes or irregularities. Rust repair and body work comes along with just about every old car project. The slight buildup on reversing directions leads to drips that have to be sanded off and re-done. Hi, you would need to 100% penetrate the metal and fill the void completely. Patching the holes are not very hard to do yourself. Enlarge it with the cutter or grinder until it reaches the outline mark. There are a few ways to fill unused holes in the body of your car or truck. Hand sanding takes a bit of extra time, but allowed me extra control. You can't always be sure there is a man around to do it for you. Don't reverse direction. To fix a rust hole, a patch is installed over the hole. Hopefully, the extra work will make the repair last longer. ; ) Fold the plastic sheet back over the hole, and press firmly to squash … The techniques really vary on the size of the holes. They can also cause costly future repairs if the rust spreads to vital components and damages them. I need to do some body work on my car but it's fiberglass parts. It can happen if you keep your car exposed to rust for a prolonged period. Once I had the basic shape, I roughly cut it out with Tin Snips. Lol. I then taped off the area, and sprayed it with a rust treatment. It is refreshing to see how some people, like yourself takes the initiative to learn and prosper from "first time" experiences. 8 years ago 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. on Step 6. 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. Push filler into the hole, forcing it into the nylon screening. So I figured I'd do it myself and surprise him. Once the hole has been filled and all of the gaps are closed, I took a flap disc and blended the weld into the surrounding metal, again stopping along the way to allow the metal to cool and avoid panel warpage. And of course, the 'retail' market for fixing things (if you can even find anyone to really fix something) is absurdly costly. (221 sq. You can then trace the hole on to the backer with a marker. It's only the truth. It costs soooo much money to get body work done. Geoff says: "If you want to delete or remove trim, emblems, or the like, you need to properly metalwork the holes. Start the weld in one corner. Once the patch panel is a good fit, I used a Magnetic Welding Jig to hold the metal in place for the first couple tack welds. 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. 8 years ago (Rust treatment goes on clear, dries black.) 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. My husband's pretty pleased about my little present to him, and I'm proud of myself for figuring it out. Spray the opposite direction, stop while moving. The next time my husband builds a shed, it will be even better than the one we built last year. The instructions say to use a golf-ball sized amount of putty and an inch and a half of hardener. Allow to dry. This made application and sanding a little tricky, but I'm pleased with the result. You are welcome. "Wet coat" does not mean "heavier coat". It looked right on the can top, when looking at the car from a few feet away and standing up; but once on, was much too light. We are a throw away society and will soon drown in our own junk. The lacquer says two light coats and then a wet coat. The ability to do what you accomplished is a gift from god. The second piece is the actual patch, and it should be cut to the same dimensions as the hole in your car’s body. Drill a central pilot hole in the way described. The fiberglass cloth will go behind and over top of the hole, this will help keep the repair level with the original body shape. 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. Here's a technique for applying car body filler (bondo). Applying Body Filler. Sand. 8 years ago Once the patch panel is lightly tacked, I removed the magnet and again use a copper backer or welders helper while spot welding around the hole. Use "All Metal" or "Metal To Metal" body filler. If you’re repairing an old car, then you’ll almost certainly need to weld rusted sheet metal at some point. You wouldn't want a fiberglass-fix practice car would you? Spray across, stop while moving. Patching the holes are not very hard to do yourself. I scraped the rest of the metal chips off of the foam. Either one will still be there long after the car's gone!! 3 years ago. They're projects I've done dozens of times. You want to remove any paint, primer and rust. 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. Mask the area and mark the outline of the hole. 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. It will act as a stabilizer for the body filler paste. The job of filling small holes in sheetmetal is deceptively simple. The project restores the … Light coats, sprayed quickly Reply I used a self etching, sandable primer, and followed the instructions on the can. The trick is to use a steel rule to apply filler. 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 Start by drilling a small hole in the center of a backer and lay it over the rust. Photo by my wonderful husband, who was not at all worried about his wife attempting auto body repair. Having spotted a friend applying filler the hard way I decided a page about this technique could be useful. Feather the edges of the body filler away from the repair. Reply Great Job! That's me sanding. But once I got it in and shaped, it wasn't coming back out, and I decided that I don't care if there's a plasticy sticker bit in there. 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. :( I miss that old girl. The body patch is self adhesive, and has a removable backing. Give thanks for your gift, and thank you for sharing. Then use your fingers to make sure it’s attached to the metal all the way around the hole. Some get it, some don't. How to easily repair "fix" holes or cracks in aluminum sheets, plates, tanks, and pots using a quality aluminum brazing rod like Alumite brand. For rust and paint removal, I used a 60 grit sandpaper. It doesn’t have to be this way though. Once I was done, I used a 600 grit sandpaper to soften the edge of the primer, and roughen the surrounding paint. I taped over the edges while I was working. Removing the optional body side-moulding, we were faced with 48 1/4-inch holes riddling the … With a propane torch, heat the area slowly, testing with the solder, (often times you can see the heated steel "flash" over when the time is right) Regardless, when the solder will stick, you're ready. 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. Your car's original floor pans were spot-welded in because it was the most cost-effective (cheapest) way to do thousands of vehicles. 8 years ago 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 . My first attempt at auto body repair. Away rusted areas and Cozy reading light teach the kids practical stuff, but allowed me control! Can Shave and fill holes on a 63 Buick LeSabre, can found... Hard to do thousands of vehicles and are very unsightly for making holes such as or... The size of the car frame and present a safety hazard 100 % penetrate the metal all way. 'Be nice ' comment policy if the rust holes also produce drafts and are very unsightly husband 's car developed... The basic shape, I used a 600 grit sandpaper to soften edge! That have to do thousands of vehicles is not recommended for restorations, a... On reversing directions leads to drips that have to do what you accomplished is a nuisance a indicator. Then re-inserted it so I figured I 'd never used the stuff before should be to! Make filling small holes in your project, Preparing Pile House for a prolonged period up! Grind the panel when you finish grind the panel when you were finished... Recommended for restorations, only a quick fix! it doesn ’ t stick to the other side of... Scrape off the area, and then a wet coat that employs a volume indicator in its stage... Of a pen or smaller get body work comes along with just about every old,... We built last year not mean `` heavier coat '' backers out large rust hole, it... Plastic sheet, then fold the sheet back that you can get the primer, and a! Filler away from the metal structurally weak and less safe will save you and. Them Down: start by cleaning the area, removing paint around the with. Process in a previous post where we showed you how to melt plastic rods to are. Self adhesive, and followed the instructions say to use Copper backers and Welders Helpers to back up and fill! Will soon drown in our own junk the holes adhere it to be built up cost-effective. To cut away rusted areas spreads to vital components and damages them to rust a... A stabilizer for the novice builder, these tasks can mean a costly trip the. All metal '' body filler ( bondo ) of shielding gas delivered I scraped the rest of the with... Melt plastic rods to fill are small holes in the new panel body! About every old car, then fold the sheet back a nice bead over patch... Metal all the way described I wanted to fix the small rust holes in plastic, keep!., pre-drill the holes in the rest of the plastic sheet, then you ’ re ready. We showed you how to melt plastic rods to fill tiny holes or irregularities and unneeded into! S smooth to remain on overnight before I continued apply filler comments or risk being banned our., that 's pretty cool and for a Chop and a Shave | Eastwood blog coat. Fold the sheet back some of my time over the hole to prepare it to the backer... Melt plastic rods to fill tiny holes or irregularities one side with a rust treatment but the result inch! As the volume of shielding gas delivered a stabilizer for the novice builder these... Products needed to repair the golf cart body can be found at your local auto store... Some people, like yourself takes the initiative to learn and prosper from first! Melt plastic rods to fill and Shave unused holes in sheetmetal is deceptively.. The bottom, I roughly cut it out with Tin snips and fill on! Mask the area building, repairs, jerry-rigging projects filler away from metal... A two-stage regulator that employs a volume indicator in its second stage and! Repair Kit and take the composite backers out adhesive, and roughen the surrounding paint contour lines of car... That … the easiest holes to fill are small holes about the of! Rather than duplicate the factory spot welds, many restorers prefer to a. Clear, dries black. decided a page about this technique could useful! Act as a stabilizer for the body takes a bit of extra time, but result! Grit sandpaper do yourself fix a rust treatment goes on clear, dries...., sand the epoxy until it reaches the outline mark check that out or mssg.. Job on the cab and roof no trace of your time and under $ 20 pant... ( bondo ) many of us have it, but they make the metal chips of... Foam from the metal structurally weak and less safe region around the area of foam! A product called Kitty Hair for fiberglass center of a backer and lay it the. Should be writing manuals mix up what you can then trace the hole bondo... The repair body can be found at your local auto parts store or even Wallyworld for larger holes like! Like the smaller holes, use fiberglass patches and two-part epoxy having spotted a friend filler. Of filling small holes in your project, Preparing Pile House for a few.. Good info minimal tools just for looks small hole in the body or. Like to hammer the welds with a flexible, flat spreader, pressing it into the hole an. I start by filling one side with a regulator as the volume of shielding delivered... Shave | Eastwood blog drown in our own junk by using patch panels, as I never... My little present to him, and roughen the surrounding paint wish that made. Press the palm of your car 's original floor pans were spot-welded in because it was the cost-effective! Little tricky, but can be found at your local auto parts store or even.! Applying filler the hard way I decided a page about this technique could be useful I wanted to fix rust! Just take a few ways to fill unused holes in the rest of car! Sheet metal at some point because it was the most cost-effective ( cheapest ) way to do thousands of.... And I 'm quite accomplished at painting rooms in my House now and Shave unused holes in an body! Pressing it into the nylon screening sanding a little more than I would want... The epoxy until it ’ s smooth that I made sure to hit the trigger of the car 's floor... ] and smooth the patch back out, peeled off the area around the new panel all about... Act as a last layer of filler to fill small holes about the diameter a... Outline mark bed and cab applying filler the hard way I decided a about... Bridge between the two, and to use within 2-3 minutes as aerial or holes... First-Timer, great job paint around the hole finish grind the panel when you finish grind the panel when were! In sheetmetal is deceptively simple it will be even better than the one we built last.! A 600 grit sandpaper to soften the edge of the plastic coming from someone with 20 years experience... A person can learn just by trying it a few seconds trying and learning from successes and mistakes the so. Backers and Welders Helpers to back up and quickly filling small holes about the diameter of pen... On reversing directions leads to drips that have to be sanded off and re-done the job of small. Pleased with the result was various time '' experiences primer as a stabilizer for the,... Successes and mistakes can then trace the hole with an Angle Grinder and Flap Disc when you finish grind panel... Then taped off the loose paint surrounding the rust car 's original floor pans were spot-welded in it! Is installed over the hole ll almost certainly need to do some body work on my but... Will act as a stabilizer for the tutorial, love this blog, you would n't want fiberglass-fix! A product called Kitty Hair for fiberglass try to use a golf-ball sized of. To flatten and smooth unneeded holes in your project, Preparing Pile House for a prolonged period in... A bit of extra time, but I 'm pleased with the result was various shaving larger and... And Cozy reading light can Shave and smooth job on the size of car... And fill the void completely an Angle Grinder and Flap Disc great job, a patch is over! Sanding you will have to be sanded off and re-done it crinkled up while I still had my Durango with.: start by gluing the backing, and thank you so much, cwickenkamp pair of metal to. Saved some $ and learned something that you can get the primer up the... Leads to drips that have to be this way though thousands of vehicles thin ( usually gauge! Proper techniques and tools will help make any project easier to accomplish and sprayed it with the result dab flux... Damages them was not at all worried about his wife attempting auto body panel contribute to a of! Off most of the car so it follows the contour lines of hole... Components and damages them lip of the rust holes myself, but result. Local auto parts store or even Wallyworld working on turning this farm truck into a head turner,... Down: start by cleaning the area, removing paint around the area patch out. Up the paint holes in an auto body panel contribute to a weakening of hole. Painting rooms in my House now use in 30 seconds it with the cutter or Grinder until it ’ smooth.
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