How to patch rust holes

This blog post will answer the question, “How to patch rust holes on a truck” and cover topics like how to fix rust holes in a truck, tips to prevent rust on trucks, and frequently asked questions.

How to patch rust holes?

Following are the steps to patch a rust hole:

  • Sand the rusted area around the hole to eliminate it.
  • Then rub the sandpaper around the gap.
  • Slightly cut around the affected areas.
  • Metal Sheets are used to fill the hole.
  • Add Bondo Glass Stratum to the mix.
  • Sand the area
  • Use a Bondo Body Filler that is within the acceptable tolerance range.
  • Use a primer for automobiles.
  • Make a mark on the ground.

9 steps to patch rust holes using fiberglass and metal mesh:

Without welding, rust holes may be repaired using fiberglass and metal mesh. Make sure you have everything you’ll need before starting the operation. If an item is missing, the procedure will not be completed. You have the option of ordering the items you need online or purchasing them from reputable vendors.

Steps are listed below:

  • Sand the rusted area around the hole to remove it
  • Slightly cut around the damaged area
  • Using Metal Sheets, Fill the Hole
  • Fill in the gaps with Bondo Glass Stratum
  • Sand the Affected Area
  • Use a Bondo Body Filler
  • Use a primer for automobiles
  • Use Metallic Paint
  • Finally, apply a coat of metal wax to it

Now I will elaborate on the guidance given above:

Sand the rusted area around the hole to remove it

Rubbing the sandpaper around the hole is a good idea. You’ll be able to get rid of all the rusty pieces this way. Wiping it is required; otherwise, you will not have a smooth, new-looking surface. It may be done by hand or using orbital sanders.

An orbital sander is the best option if the rust hole is huge. Alternatively, you may attach the sandpaper to the drill and use it to remove the rust.

Slightly cut around the damaged area

If you believe cutting around the problem area won’t hurt, go ahead and try it. You may use a saw or a cutter to do this. It depends on the sort of material you’re cutting.

Using Metal Sheets, Fill the Hole

Metal sheets may now be used to fill that area. You may either adhere it to the rusty hole or place it on top of it. If you’re going to patch the corroded hole with fiberglass resins, you’ll need to grab it while doing so.

It might cause rashes on your skin, so make sure you’re using plastic gloves when filling the holes. The fiberglass will adhere to your hands if you don’t use gloves.

You may also use plastic to strengthen the structure. It aids in the bonding of the fiberglass and metal sheets. Put another layer of fiberglass adhesive on top of the plastic once it has been applied.

Fill in the gaps with Bondo Glass Stratum

Fix the Bondo glass fillers using a spatula. Bondo glass coating is a thicker fiberglass variant. It will secure the fiberglass and metal sheets while also improving the overall look. Bondo glass filler has a comparable look to plaster of Paris in terms of appearance.

Sand the Affected Area

After you’ve completed the aforementioned steps, allow it half an hour to totally dehydrate. It’s time to mold it now. Remember to set the orbital sander to a hundred revolutions per minute while you assemble everything. This will help you finish the work faster.

Once you’ve achieved your desired form, be sure to clear up any dust and only begin sanding once you’re certain it’s totally dry.

Use a Bondo Body Filler

Apply the regular Bondo Body filler after you’ve completed the previous steps to make it more powerful. Repeat the procedure, being careful to smooth it with sandpaper or an orbital sander as soon as it has dried.

Use a primer for automobiles

The automobile primer is the ideal choice for steel or iron body constructions. It is available for purchase at any big department shop or mechanic’s outlet. Priming is required. Even after you’ve removed the rust, your metal object won’t look wonderful if you don’t prime it.

Use Metallic Paint

Metallic paints may be used to color the Bondo look on the metal component. Make certain you choose high-quality colors. High-quality colors will prevent it from ripping off or rusting your metal again. Because one application is insufficient, you should apply two or three coats of spray.

Finally, apply a coat of metal wax to it

Metal wax is used as the last stage in this operation. Make sure the spatula or towel you’re going to use to polish is completely dry. Use a dry spoon to apply metal wax instead of a moist spoon. Because the coating has a water layer, the metal will begin to oxidize anew.

It’s important not to neglect this step since waxing is required. The primary goal of waxing the metal is to stop it from becoming any worse.

Materials Needed
Body filler
Metal mesh
Fiber glues

How to patch rust holes on vehicles?

Follow the steps given below to patch rust holes on vehicles:

  • Prepare the space.
  • With a wire brush wheel, eliminate the corrosion.
  • Remove any remaining rust with sandpaper.
  • Weld any necessary repairs and repaint the truck bed
  • Make use of body filler
  • Prime using a primer

Here’s a quick rundown of the procedure.

Prepare the Environment

Here’s how you can do it:

  • Preparing the surface and eliminating all of the corrosion is the first step in repairing a corroded truck bed. You’ll only be able to determine the actual degree of the harm after that.
  • Start by masking off any areas that aren’t impacted by the rust. Use many layers of paper or sticky tape for further protection. 
  • For the corrosion removal procedure, you’ll need a scrub brush and some sandpaper, and you don’t want to scratch any of the surrounding regions.
Tools Needed
Scrub Brush

With a wire brush wheel, eliminate the corrosion

Steps of eliminating corrosion with wire brush wheel:

  • After you’ve completely covered the parts of the truck bed that haven’t rusted, start removing the rust using a drill and a wire brush wheel. 
  • This is a more aggressive procedure that involves a lot of lube and physical effort, but the aim is to remove the majority of the rust as soon as possible. 
  • Don’t worry if you break through the bed or expand a gap in the process. You want to keep going until you can’t take any more rust off.
Tools Needed
Wire Wheel

Remove any remaining rust with sandpaper

Steps of removing rust with sandpaper:

  • After you’ve removed all you can, go over any areas with 80-grit sandpaper to remove any remaining corrosion. 
  • Keep in mind that rust may spread under the surface and harm painted surfaces. 
  • Scrape some paint around the perimeter of the sanded area to confirm that all of the corrosion has been gone.
  • Now sand the area using 150-grit sandpaper to make it smooth. This will aid in the adhesion of paint and patching material.
Materials Needed
80-girt Sandpaper
150-girt Sandpaper

Weld any necessary repairs and repaint the truck bed

After cleaning and drying the truck bed, apply a corrosion prevention primer to any uncovered metal. Apply an even layer, being careful not to miss around the margins of any gaps, as well as the base of the bed where paint may have peeled away.

This is where you would weld a patch in place if you were intending to do so later in the procedure. Body filler, on the other hand, is a safer and more economical option for most individuals.

Make use of body filler

Body filler is a useful material for filling holes left by rust and corrosion. However, before you start mixing the filler, make sure you apply any patching gauze or other substances that are included with your patching kit. 

Steps of applying body filler:

  • After you’ve finished applying the patching mesh, you may start mixing the filler, being sure to follow the product’s directions. 
  • You must carefully follow these directions because if the ratios are off, the filler will solidify too soon or not at all.
  • Similarly, you should be mindful that the filler will start to set as soon as you finish mixing it. 
  • Because the time is ticking, you’ll want to go to work as soon as possible. You should be OK as long as the hole is entirely filled. Fortunately, you don’t have to bother about it appearing attractive just yet.
Material Needed
Body Filler

Prime using a primer

Steps of applying primer:

  • Apply an automobile primer to the repair and any uncovered metal after it has been cleaned out to your approval. 
  • After the primer has dried for approximately an hour, you’ll want to sand the area using 400-grit sandpaper. 
  • Apply a second layer of primer once you’ve finished sanding and let it dry before leveling it out with the same paper.

Here’s the best primer:

Rust-Oleum Rusty Metal Primer (7769502)

Benefits of Rust-Oleum primer:

  • Provides a rust-controlling formula.
  • Provides strong paint and top-coat adherence.
  • Leaves a smooth, one-of-a-kind finish.
  • Simple to use
  • There is no need for dilution or preparation.

Frequently Asked Questions(FAQs), “how to patch rust holes?”

Can rust holes be fixed?

While fixing a corrosion hole is not difficult, it does need time, particularly if you choose to repaint the car yourself. If the rust-caused hole is not in a load-bearing component of the automobile, such as the frame, glass fiber or body filler may be used to patch it.

How do you fill holes in metal without welding?

Tape or Epoxy

No-weld hole repair alternatives include epoxy and tape. When fixing a little hole rather than a large rip, these do-it-yourself methods work well. Steel and metal are patched using specialty epoxy and tape materials.

How do you fix rusty holes in metal?

Step 1: Scrape off any loose or flaking paint or rust using a wire brush. 

Step 2: Sand out the tough rust spots using a grinder. 

Step 3: Because painted corroded metal may seem uneven, use Bondo to fill in any holes or divots created by corrosion and previous paint.

How do you fix metal without welding?

Loctite Epoxy Weld Bonding Compound is another method for bonding metal. It’s the strongest option for bonding most metals, like iron, steel, metal, bronze, silver, and pewter, and it’s a simple alternative to welding.

What is metal-epoxy?

Epoxy is a high-strength glue that comes in a two-part syringe with resin and hardener, therefore the term “two-part epoxy.” When these elements are combined, they form strong, long-lasting connections. For example, if you need to fix metal, you’ll need a good metal epoxy.

Can you use wd40 on car rust?

Because your automobile is important to you and you want to take excellent care of it, WD-40 is a great way to eliminate rust from metal without hurting the paint. To eliminate surface corrosion, just spray it on the corroded surface, wait 10 minutes, and it will begin to act on the rust.


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