How To Repair Sheet Metal Door Rust

Sand the damaged area use sandpaper or a sanding block to remove any existing rust or paint from the damaged area.

How to repair sheet metal door rust.

While sanding the rust from the surface of the metal the rust damage will be exposed and there is a chance that the rust hole you need to repair will grow larger. Fixing surface damage on a metal door step 1. The area should be sanded until it. How to repair rusted metal without welding.

Leave the rusted area exposed. I had a major rust problem in my 1989 mitsubishi montero ls v 6 four door and thought giving glue a chance would at worst demonstrate what not to do and at best bond some new steel in place of rust with a minimum of body filler. Thanks to modern chemistry and manufacturing we now have two part epoxy panel adhesives that are strong and flexible enough to bond metals together more or less permanently. Cover the surrounding metal with masking paper and tape.

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. Cut some sheets of masking paper to size with a sharp pair of scissors. Press them flat against the surface of the metal then secure the edges with masking tape. The most permanent repair to a hole in sheet metal is to weld the hole shut.

The complexity of welding increases as the thickness of the material decreases.