Rust Prevention and Removal Part II: Patch Panels or Replacement

In our last piece on rust prevention and removal we covered the basics– enough to get the ball rolling and prepare yourself for the task at hand. In this piece we take it a bit further and give some tips on the ways to tackle rust removal, specifically using patch panels. But remember, every job is different and no two things are going to rot the same.

Best Case Scenario

While the solution entails getting down to the bare metal, the process can vary depending on what part of the vehicle is affected. If rust is just beginning to form, and there is no real damage done to the metal underneath the car, go ahead and clean the problem area as best as possible.

If dealing with rust on thicker metal, don’t be afraid to bust out the power tools. They’re great for heavy jobs or large surface areas of deterioration. Smaller and lighter tools will be better suited for thin sheet metal, or getting into tight corners. And regardless of where the rust lives, be ready to bring some elbow grease.

Once you get through the rust, work on preventing its return. Rust Converter is a water-based primer that uses a chemical reaction to stop rust you may have missed from spreading. It also works to prevent future rust from starting. Since it is a primer, you can apply a top coat directly over it. No two products work the same however, so be sure to stick to manufacturer’s instructions for guidance.

A Little Worse For Wear

In severe cases, the process will be more intensive. Expect to spend a few hours or even days addressing a serious rust issue. Remember, it should never be about how quickly you can get the job done, but about how well you can do it. And again, each case will vary– so get ready for some creative problem solving.

The proper tools are also important. For a bigger job, that might include: a welder, grinder, hammer and dolly set, spare sheet metal, paint, and body filler.

In a situation where the metal has been completely eaten away, there are two choices — patch or replace.

If the affected area is something like a fender, hatch, or door where the panel can easily be completely removed and replaced, then you might find it easier to simply do so. It can definitely be more expensive as far as materials, but this method can also take up significantly less time.

If the rust is on something structural to the car, like a deck filler panel, a quarter panel, or just about anything that is held in place by spot welds, it won’t hurt to simply patch the panel as opposed to replacing the whole thing. Sure, it won’t be as nice as the original, but it will cost a lot less. And if you take your time, you’ll be surprised by how good it looks.

Patch Work

In the case you are performing a patch job, your best medium will be a welded patch panel. This route will produce the cleanest and longest-lasting results. You can use sheet metal from a local supplier, but you risk it not being a perfect match. A good deal of experience is recommended before taking on a project like this. If you don’t feel comfortable in your welding skills, consider calling in a buddy or practicing on scrap metal or an old fender. >>> Curious how to fabricate patch panels? Click here to learn more.

When tackling a patch panel, there are a few things to keep in mind.

First, tread carefully with the big toys. We all know power tools produce heat when they are in contact with metal. Sheet metal is thin and will warp easily when too much heat is applied. Yes, there are manufacturers on the market who have built specialty tools for this kind of job, but do the homework and make sure you select the right one for the task. And remember — don’t rush this job. Careless work will only lead to more headaches.

The second thing to keep in mind is to hope for the best, but prepare for the worst. Rust spreads fast, and sometimes the affected area can be much wider than you originally anticipated. If this is the situation, don’t be discouraged. Just keep focusing on removing all that rust. Don’t cut corners; work slowly and conscientiously, and you’ll see positive results.

Once the panel has been patched, it will need to be ground down to hide the welding stitches. No elixirs or potions need to be applied, just elbow grease and some body filler (a little goes a long way) before applying primer and paint.

A Stitch in Time Saves Nine

Sure, taking the time to seamlessly patch in a new panel means more labor and a longer project timeline. But when all’s said and done, you can rest easy that the problem won’t be coming back anytime soon.

Rust is a natural occurrence, but that doesn’t mean it can’t be avoided. The importance of prevention cannot be stressed enough. Proper and regular cleaning of your vehicle, as well as adding the necessary layers of protection is the best defense. If it seems like a task, just ask yourself “Would I rather scrub or cut?”