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Is there any way to repair rust spots so the rust will not return aside from putting new metal on it? I've used Bondo before but it rusts again after a while.
up to a point yes-
problem is- unless you can see the other side and treat the rust it'll come back- surface rust is one thing- rusted body metal you really can't tell-
as in most cases- you're better off sanding the rust off- or at least get right down to the bare metal- the old art was to cut the rust out and braze new metal in- some were experts at soldering-
You have to cut the old rusted metal out, no surface treatment will fix deep body rust. The area can then either have a new piece of metal welded or bonded in, or it can be replaced with body filler and/or fiberglass. You still have to treat and seal around the area you cut so that rust cannot start somewhere else, and if the rust was being caused by water getting trapped somewhere, you either have to fix it so that water can't get into the same area again, or you have to make sure it can drain out.
The reason your Bondo didn't work is you have to get all the old rust, not just cover it up. Most the time when rust sets in, its because the panel has rusted completely through from the inside.
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