How to Install a Rust Replacement Panel

Since the invention of the automobile, vehicle owners have been battling rust in the cars' body panels. Rust will deteriorate a vehicle body in a short period of time if left unattended. Professional body shops can replace rusted panels, but some experienced vehicle owners can replace the panels themselves to cut costs. Panels such as rocker panels, quarter panels and door panels are susceptible to rust and damage because of their locations on the vehicle. There is a wide variety of manufacturers who reproduce repair panels for just about every vehicle on the market.

Instructions

1

Hold the new patch repair panel up to the rusted panel and draw the outline of the new panel onto the car with a marker.

2

Cut out the rusted panel with a metal saw, using the marked outline as a guide.

3

Sand the area around the panel 3 to 4 inches back from the hole you have cut with an 80-grit orbital sander. Sand down to bare metal. Sand the edges of the new panel using the same procedure.

4

Clamp the new panel in place with locking c-clamps. Ensure that the panel is lined up correctly for a uniform and flush fit.

5

Tack weld the new panel into place.

6

Make numerous short 1-inch welds around the panel. Allow the metal to cool completely after making each weld. Otherwise the panel could warp.

7

Grind the welds down smooth with a electric or air-powered grinder. Grind a little at a time to avoid grinding away too much of the metal.

8

Apply a layer of body filler over the new panel with a putty knife and allow to set.

9

File down the high spots in the body filler with a body file when the filler has dried enough to be scratched away with a fingernail; it should still be slightly tacky, but mostly dry. Allow the filler to cure according to the product directions.

10

Dry sand the filler with a 100 to 200-grit sanding block until it is flush with the panel.

11

Wet sand the panel with 300-grit sandpaper or sanding block by hand until the panel and panel edge are smooth. Dip the sandpaper or sanding block in water to get it wet.

12

Spray automotive primer onto the panel and allow to cure. After curing, wet sand the primer smooth with 300-grit sandpaper.

13

Paint the panel with automotive paint to match the vehicle's finish.