Hello this is Donnie Smith and today we are going talk about rust repair.
This is part I of the video series where we are going to talk about cutting out a rusted
damaged area and welding in a new piece of metal.
The first thing you want to do is determine, where the rust is located and the extent of
the rust.
Rust is really not that hard to find.
Obviously there is a hole that is easy to find, but a lot of time the rust does not
eat all of the way through the metal you may be able to repair the rust without having
to cut out a section and add a new piece in.
Rust actually starts forming on the metal.
For different reasons it could be due to salt on the roads that cause rust, it could be
that mud is getting caught behind this area and not being cleaned out and just that moisture
has always been there causing it to rust.
There is a lot different reasons you could have had a repair in this area before and
didn’t have the proper corrosion protection added back to the metal.
But for whatever reason the rust starts forming on the metal.
Now at this point you can't see it, but as it starts spreading and growing it starts
pushing the paint out bubbling the paint.
Now when you see bubble paint that is the first indication that there may be rust underneath
it.
This is the time that you want to get this fixed to repair the rust and hopefully you
know you won't have to even cut a patch panel repair panel out.
To determine how bad it is the first thing you can do is get a screw driver or scratch
off and push in on the bubbled area.
With these flakes some of the outer area rust out, but it does not push through.
Chances are you can clean that area up and take it down to bare metal properly.
Use corrosion protection to prevent this from happening again and go ahead and re-finish
the parts.
There is a chance that you can repair this without cutting out an area and welding in
a new panel.
However, if it does push through or it is too extensive to repair it is going to require
cutting to sever the rusted surface out and replace with a new one.
Now what you want to do before you start cutting this can't determine how big the area is just
because you have a 1/4 size hole does not mean that the rust is just in that area.
Chances are it is spread behind the panel more than that.
So you want to grind it all the metal on the outside and make sure all the outside rust
is off and then you can determine how thick the metal is on the edges.
You want to make your patch big enough to where is welded the new patch is going to
be welded on to good metal.
So most of the time you are going to have to extend out where the rust will actually
is several inches to three or four inches past that to assure that you are going to
be cutting welding back into good metal.
So once you have determined this the easiest way out you have found to market and now about
where the good metal is at is just to use masking tape.
It is really not that necessary to make the most perfect measured out mark lines because
whatever you cut out is what you are going to use for your template.
I use that masking tape edge as the line to make the cut at and also lot times it is by
edges by the phalange and where the metal wraps around the phalange there is going to
be some spot welds that you may have to drill out.
So once I have my tape laid out I will use a cut off saw to make the cut and you got
to be careful if its round inner panel there that you do not want to cut into both panels
so you may have to just cut the outside surface taking care not to cut all the way through
other components of the car.
So cut with your line from the tape, make the cut all the way around the rusted area
and drill out the spot welds if there are any on the back side.
Now you want to make sure that you are careful doing this because you want that piece to
come out just as full as it can.
Because you are going to use that and there may be times where you know the whole edge
was rusted by the edge and you can't really use the entire piece.
But you can kind of use some masking tape again to kind of lay out the way it should
be, but try not to damage that area.
This is going to be used for your template which we are going to talk about in an upcoming
video.
So you have got to cut out, you know you may want to make sure that your edges are all
good metal and we will talk more about cleaning up the area we are going to weld to and how
to fabricate new piece in an upcoming video and we will use some metal.
Now there is another option to this they do build a lot of patch panels, repair panels
that you can buy which is that is real nice it prevents the need to have to try to fabricate
these metal pieces, but with just a few tools you will be able to make some of these pieces
yourself and there are some areas that is real complex and got a lot different body
lines going on make it very difficult to make these pieces without the right tools.
But a lot of the patch panels are you should be able to make those just with some steel
so that wraps it up for this video and be watching for more rust videos as we go through
the process of forming the piece of proper corrosion protection steps to take to welding
the piece in, grinding it and getting it ready for primer and paint.
If you like this video, be sure to go down below this video and give us like and share
this with your friends.
I will see you in the next video.