How to Repair Rusty 18 Gauge Steel Panels

Rust is metal's natural enemy. A tiny chip or a scrape combined with a bit of moisture is all it takes to get the process in motion. Without the proper treatment, it is only a matter of time until the metal has succumbed to the voracious appetite of the corrosive monster. The fight doesn't have to be lost though. The damage can easily be reversed by cutting out the rust, and replacing it with fresh clean metal.

Instructions

1

Grind off all of the paint surrounding the area being replaced. Stripping the area down to bare metal will expose hidden rust, and provide a proper welding surface.

2

Draw a cut line around the area that will be replaced with a permanent marker.

3

Put on ear protection and safety glasses then cut along the marker line with a cutting wheel.

4

Create a template by tracing around the removed section of metal onto poster board with a marker.

5

Cut out the template with scissors to fit the repair area as close as possible.

6

Trace the template onto the metal patch panel with a permanent marker.

7

Cut out the patch panel with tin snips or a cutting wheel. Use what works best for the job.

8

Fit the patch panel to the repair. Make any adjustments that may be needed to ensure a proper fit.

9

Secure the panel in place with welding clamps. Strong welding magnets can also be used if clamps are not an option.

10

Put on a welding helmet and welding gloves and place a tack weld on each side of the panel using a mig welder. It is best to use a few tack welds at first to ensure the panel has the proper fit.

11

Weld the patch panel in place using small inch-long stitch welds. Alternate the sides of the panel with each weld. Concentrating on one spot can overheat the metal resulting in burning through the metal and cause the panel to warp. Be sure to allow the metal to cool between welds.

12

Grind the welds flush with the panel. A hammer and dolly may be needed to straighten any imperfections to the repaired panel.