How to Fix Auto Body Rust Holes

Rust holes in the body of a car can cause the frame of the car to weaken and can cause safety issues. Fixing a rust hole in a car requires the use of several automotive repair tools to apply a patch to the rust hole.

Items Needed

• Disc grinder


• Metal cutting disc


• Tape measure


• Permanent marker


•  1 piece of sheet metal (12-Gauge)


• Metal shears


• Drill


• 1/4 Inch carbide drill bits


• Rivet gun


• Rivets


• Auto body repair putty


• Sanding block


• 80-Grit andpaper


• Automotive primer


• Automotive paint

1. Use a disc grinder with a metal cutting disc to cut away all the rusted sheet metal around the hole.


2. Measure the size of the hole with a tape measure. Determine the widest and longest points of the hole, and add 2 inches to the measurement.


3. Use a permanent marker to draw a hole according to your measurements on a piece of sheet metal.


4. Cut the hole out using a pair of metal shears.


5. Place the piece of sheet metal over the hole so that there is about 2 inches overlapping onto the surface of the car.


6. Drill holes through the sheet metal into the body of the car using a drill fitted with a carbide bit. Drill a hole about every 3 inches.


7. Use the rivet gun to insert a rivet into each drilled hole to secure the sheet metal piece to the car.


8. Spread an even layer of auto body repair putty over the sheet metal piece and about 1 inch beyond the sheet metal onto the surface of the car. Allow the putty to dry for about 6 hours.


9. Use a sanding block fitted with 80-grit sandpaper to sand over the sheet metal patch and surface of the car until the surface is smooth and even.


10. Spray a coat of automotive primer over and around the sheet metal patch. Let the primer dry according to the directions listed on the container. After the primer has dried, add another coat of primer. Allow to dry thoroughly.


11. Spray a coat of matching automotive paint over the layers of primer to cover the repair.