How Ti Epoxy Sheet Metal Behind Rust Holes

Preparing the hole use coarse sandpaper to remove paint rust oil and dirt from the surrounding metal in a minimum 1 inch wide border around the hole on both sides of the metal.

How ti epoxy sheet metal behind rust holes. Even banging on it will make you think you are banding on sheet metal. Make sure that no air remains between the two part epoxy putty and the surface of the metal. Cut some sheets of masking paper to size with a sharp pair of scissors. I used a piece of pvc pipe a vice mount miniature metal break and body hammer kit.

Coat the area inside the hole thoroughly with miracle paint to prevent further rusting then make a patch of 3 layers of fiberglass mat soaked in miracle paint and apply it over the rust hole. After slicing the patches out with a cutoff wheel next came the bending hammer and dolly session until the patches matched the holes and fit snug and flush into the flanged seat. Cover the surrounding metal with masking paper and tape. Place the mixed two part epoxy putty on the area of the metal you need to repair and work the epoxy putty onto the surface of the metal by apply pressure on the epoxy putty with your thumbs and fingers.

When dry overnight you will not believe how strong this repair. Start by drilling a small hole in the center of a backer and lay it over the rust. If the hole needs to contain a liquid a rubber washer can go on the sheet metal screw to render it water tight. Press them flat against the surface of the metal then secure the edges with masking tape.

You can then trace the hole on to the backer with a marker. Leave the surface rough but clean. In an emergency whittle a plug from a scrap of wood or tree branch and tap it into the hole. I then used the templates to trace out the patch panels on some sheet metal.

Notice the heavy bead 1 4 inch of adhesive along the entire bare metal contact area for positive adhesion and rust protection. Perhaps a simple rivet or sheet metal screw can be secured in the hole. Leave the rusted area exposed.