How to Fill Holes in Autobody Metal

Unsightly holes in the body of an automobile can be fixed without having to break the bank or sending your car to an expensive body shop. Patching a hole in any metal automobile part, whether due to accident, rust or other unfortunate situation, requires the tools and know-how to tack weld. Once the weld is finished and the patch is sanded, all you need is a coat of primer and a new paint job and it's like the hole was never there.

Instructions

1

Grind down the area around the hole with a 4-inch grinder so that there is no paint, primer or rust left. Any of these materials could prevent the flux from adhering properly.

2

Cut the hole into a round shape with a hole saw or plasma cutter.

3

Place a piece of cardboard behind the hole and trace a template on it with a pencil.

4

Cut out the stencil and lay it on a piece of sheet metal.

5

Transfer the template by scribing the circle onto the sheet with a blade or drawing it on with a marker.

6

Put on the welding helmet and cut the circle out of the metal sheet with a plasma cutter. This creates the metal plug that will fill the hole.

7

Place the metal plug in the hole in the car and hold it in place with the help of a heavy duty magnet.

8

Tack weld the plug in place with at least four welds. Be sure to wear your welding helmet and heavy work gloves when working with the flux and acetylene torch.

9

Remove the magnet from the back of the plug so you can finish the weld.

10

Finish the weld.

11

Sand down the flux with an electric sander equipped with 40-grit aluminum grade sandpaper until the flux and sheet metal are flush with the rest of the car body.