Repair of Corrosion or Cracks in Body Panels

PROCEDURE

1. Remove paint from the damaged area, as well as from an area several centimeters around the damage, using a sanding attachment or wire brush mounted on a drill.

2. If you do not have these tools, you can use sandpaper.

3. After the paint is removed, assess how much the metal is affected by rust. Based on this, decide whether to replace the entire panel (if possible) or repair the damaged area.

4. New body panels are not as expensive as many people think. Often, installing a new panel is faster and more effective than attempting to repair large corroded areas.

5. Remove all components from the damaged area, except those that can serve as a template for restoring the original panel shape (for example, headlights).

6. Then use tin snips or a hacksaw blade to cut away the rusted and corroded metal.

7. Bend the edges of the opening inward to create a small recess for the primer.

8. Clean the affected area with a wire brush to remove rust dust from the rest of the metal surface.

9. Paint the affected area with anti-corrosion paint. If there is access to the reverse side of the rusted area, treat it as well.

10. Before applying primer, the opening must be covered in some way. This can be done using aluminum or plastic mesh, or aluminum tape.

11. To cover a large opening, it is best to use aluminum or plastic mesh, or fiberglass.

12. Cut a piece of mesh roughly matching the shape and size of the opening, then place the mesh over the opening so that its edges are below the level of the surrounding surface.

13. The mesh can be secured by applying several drops of primer around the perimeter.

14. Aluminum tape should be used for small or very narrow openings.

15. Unroll the tape, cut a piece of the required length and shape, then remove the protective backing (if applied to the tape) and cover the hole. If one layer is not thick enough, apply another layer of tape.

16. Press the edges of the tape with the handle of a screwdriver or a similar tool so that it adheres tightly to the metal.