Auto Rust Repair: How To Cut Out A Rust Hole - Rust Repair Part 1

Uploaded by ButlerCollision on 05.02.2012

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.