How Ti Epoxy Sheet Metal Behind Rust Holes

Make sure that no air remains between the two part epoxy putty and the surface of the metal.

How ti epoxy sheet metal behind rust holes.

I then used the templates to trace out the patch panels on some sheet metal. You can then trace the hole on to the backer with a marker. Leave the rusted area exposed. Perhaps a simple rivet or sheet metal screw can be secured in the hole.

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. I used a piece of pvc pipe a vice mount miniature metal break and body hammer kit. Cover the surrounding metal with masking paper and tape. 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.

If you can t see the hole through the backer you can shine a light directly on the back or from behind the hole and it should help you see better for tracing. Leave the surface rough but clean. Also the no contact inner areas were brush coated with eastwood s. When dry overnight you will not believe how strong this repair.

On the back side of the metal use a putty knife or the applicator supplied with the kit to coat the border with epoxy filler. Notice the heavy bead 1 4 inch of adhesive along the entire bare metal contact area for positive adhesion and rust protection. In an emergency whittle a plug from a scrap of wood or tree branch and tap it into the 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.

If the hole needs to contain a liquid a rubber washer can go on the sheet metal screw to render it water tight. 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. Press them flat against the surface of the metal then secure the edges with masking tape.