Patch panel/Rust repair
Postmaster
Joined: Nov 2000
Posts: 2,557
Likes: 2
From: Texas
Patch panel/Rust repair
I just thought I'd drop a post here to show how a basic rust repair is done with a patch panel . The fullsize images are in
my gallery or you can click the pictures if you are looking for more detailed pictures.
Photo 1: Clean the effected area thoroughly.
Photo 2: Remove just enough material to get a look at the backside. Make sure and remove only what needs to be removed and still make a simple patch.
Photo 3: Cut your patch from the same guage steel, cut/form to fit so as to allow at least a slight gap around the perimeter.
Photo 4: Spot weld the patch in and work the metal with a hammer so as to maintian a flush working surface. The care you take here will pay off in the finishing stages. Move your welds to opposite sides so as not to warp the panel. Weld a few, rest, weld, rest, etc.
Photo 5: Grind the welds and sand the patched area with 40 grit followed by 240 grit and finally a 400 grit. Now the area is ready for finishing.
Photo 6: Apply filler, sand, and prime. As with all bodywork, you will require a bit of filler unless your a metal working genius and do it for a living.
my gallery or you can click the pictures if you are looking for more detailed pictures.
Photo 1: Clean the effected area thoroughly.
Photo 2: Remove just enough material to get a look at the backside. Make sure and remove only what needs to be removed and still make a simple patch.
Photo 3: Cut your patch from the same guage steel, cut/form to fit so as to allow at least a slight gap around the perimeter.
Photo 4: Spot weld the patch in and work the metal with a hammer so as to maintian a flush working surface. The care you take here will pay off in the finishing stages. Move your welds to opposite sides so as not to warp the panel. Weld a few, rest, weld, rest, etc.
Photo 5: Grind the welds and sand the patched area with 40 grit followed by 240 grit and finally a 400 grit. Now the area is ready for finishing.
Photo 6: Apply filler, sand, and prime. As with all bodywork, you will require a bit of filler unless your a metal working genius and do it for a living.
Last edited by Rosati; Jan 22, 2003 at 10:21 PM.
Postmaster
Joined: Nov 2000
Posts: 2,557
Likes: 2
From: Texas
Patch panel/Rust repair
I am planning to do a page on my website but it will have to later down the road. When I do finally get around to it, I will submit it to FTE for a tech article.
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Senior User
Joined: Nov 2001
Posts: 214
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From: Kingfisher OK, USA
Patch panel/Rust repair
Very cool Krosati, I will be anxiously waiting, as I am sure several others will be too!
Cory
Cory
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Admom
Joined: Feb 2001
Posts: 9,414
Likes: 201
From: Silver Springs
Patch panel/Rust repair
Hey K.Rosati - I also can't wait til you do that tech article and hopefully we can leave this thread anchored up here with a link to it. You know as well as I do how many don't look for the tech articles. This thread can be a direct link.
Thanks for the great info.
Thanks for the great info.
Postmaster
Joined: Nov 2000
Posts: 2,557
Likes: 2
From: Texas
Patch panel/Rust repair
I haven't found one yet. Most books I find on welding are general in the sheetmetal area and don't do a step by step. I am still looking anyway because since I started this truck, my welding skills are improving but it's real hard to get nice welds that are consistent in flowing all the way through. Most of the work I have done has had either a blow through or didn't fully weld and I had to reweld on the other side. Sometimes I get it right but its hard. The trick is to get the right feed setting, heat range, and moving the gun at the right speed. I'm not consistent at this point and rely on spot welds and short 1/4" welds.
Post Fiend
Joined: Jan 2002
Posts: 5,859
Likes: 7
From: USA
Patch panel/Rust repair
Originally posted by krosati
I haven't found one yet. Most books I find on welding are general in the sheetmetal area and don't do a step by step. I am still looking anyway because since I started this truck, my welding skills are improving but it's real hard to get nice welds that are consistent in flowing all the way through. Most of the work I have done has had either a blow through or didn't fully weld and I had to reweld on the other side. Sometimes I get it right but its hard. The trick is to get the right feed setting, heat range, and moving the gun at the right speed. I'm not consistent at this point and rely on spot welds and short 1/4" welds.
I haven't found one yet. Most books I find on welding are general in the sheetmetal area and don't do a step by step. I am still looking anyway because since I started this truck, my welding skills are improving but it's real hard to get nice welds that are consistent in flowing all the way through. Most of the work I have done has had either a blow through or didn't fully weld and I had to reweld on the other side. Sometimes I get it right but its hard. The trick is to get the right feed setting, heat range, and moving the gun at the right speed. I'm not consistent at this point and rely on spot welds and short 1/4" welds.
your on your way to being what we called
a bodyman !(I'm since retired from the trade)
short spot welds should be all your doing on sheetmetal ,skiping around the part being welded, as to not overheat.
also not to overheat when grinding down sheet metal causes oilcaning
from your article here and your quote above!
your learning
but the biggest factor in it all is practice practice
and not being afraid of making mistakes !
I can't stress enough about shop safety though
from chemicals and fumes !
please becareful ! follow all precautions to protect yourself
Some of us didn't!
I've lost alot of friends in this trade!
Great job and post!
Rich
