How To Repair Rust With Sheet Metal

Pull the trigger of the angle grinder and run the spinning 60 grit flapper wheel over the rusted area of the metal.

How to repair rust with sheet metal. How to repair rust without welding. And maybe the epoxy would result in a more rustproof seam. Make sure to get as much rust off the surface at this point as possible. The first thing to do is carefully cut away the rusted out area.

Lay the removed section on a piece of fresh steel and trace the outline. You can then cut. 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. This should be the result with the bad part of the panel removed.

Attach a 60 grit flapper wheel to a 4 5 inch angle grinder and put on your safety glasses. Make sure not to cut through the underlying metal. For an inexpensive all purpose choice get a aws er70s 3 steel wire. Sand the area with a coarse grit sand paper using a circular motion.

If it gets dirty the weld won t turn out very strong. The first step was to cut out the rust. The complexity of welding increases as the thickness of the material decreases. 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.

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. Use aws er70s 6 steel wires for a higher quality.