Metal patching without welding
cheap easy and solid
Repair Rust and Holes with the No Weld Hole Repair Kit from Eastwood
http://www.eastwood.com/no-weld-hole-repair-kit.html No Weld Hole Repair Kit Item #13661 The Eastwood No Weld Hole Repair Kit provides a quick, weld free solution to plugging 2 inch Dia. or less holes in steel, aluminum, fiberglass and plastic body panels while minimizing sanding damage and the amount of required surface preparation. Repair holes caused by rust and corrosion. For Best Results, Eastwood also offers: Pre Painting Prep Aerosol 11 oz Item #10041 Z The final step in surface prep—PRE™ Painting Prep Proper surface preparation is one of the most important factors in helping you achieve a high-quality final finish. Our specially formulated PRE Painting Prep removes dirt, wax, polish, grease, silicone, buffing compound, even road tar, ensuring a clean surface that's ready for final painting or powder-coating. Removes silicone, wax, polish, grease and dirt Helps promote paint adhesion Easy spray-on, wipe-off application Eastwood Contour Premium Body Filler .8 gal Item #13520 ZP Contour™ 1-step Premium Body Filler actually inhibits rust and self-etches! Save time in your shop with our "all-in-1-step" custom-blended premium body filler. It contains rust inhibitors to prevent corrosion long after painting, and its unique self-etching properties bite into the surface for maximum adhesion. A great "1-2 punch" to help finish bodywork faster and more effectively! Rust inhibitors prevent corrosion Self-etching properties create excellent adhesion Superior coverage and feather-edging ability 1-step process; no glazing putty required Watch this video to see us fix a rusty hole in a car door with the Eastwood No-Weld Hole Repair Kit.
How to repair a large rusted out area on your vehicle
I'm just showing one way of a quick Diy repair without using a welder and patch metal this is a fairly easy process with little experience and tools needed, there are much better ways of doing this (welding on a jobber panel or patching with metal) but this is just a very cheep way no welding or experience in metal work needed and if the vehicle is rust proofed after the repairs and every season afterwards it will last for many years. Tools: Grinder or rotary tool Hammer Paint brush Paint scraper Palm sander (optional) Mixing board (old piece of sheet metal) Sanding block (block of wood) Body File Materials: Grinding Disks Rust Mort (if you can't remove all the rust) Short or long stand fiber glass filler (bondo Glass) Fiber glass cloth for cars not boats Body filler (Polyester body filler) Spot putty Wax paper (the stuff you use in the kitchen) Sand paper 80, 120, 240 grit Primer (use the stuff for autos only) Top coat (color match paint) Clear coat
REPAIRING A WHEELARCH
This wheelarch, like many others, is double skinned. This video shows repairing it with pingun and panel pullers.