How To Fix Rusted Car Body

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No one likes to look at their pride and joy and see ugly rust spots on it. As well as being unsightly, it is a sign that your vehicle is slow eroding away right before your eyes. In this article “How To Fix Rusted Car Body” I will share with you four techniques on how you can tackle that pesky rust to preserve the life of your car and also get it looking great again too.

I have done the leg work for you and found what in my opinion are the four best video guides on YouTube to talk you through the process to remove and address rust on your car’s body.

No Welder? No Problem!

Here is a fantastic video from Chris Fix where he shows you how to deal with some fairly substantial rust patches on a car. I like this video a lot because this can be easily done at home with basic products you can buy in any decent automotive DIY shop. Here is a list of the products you need for this:

  • Disposable gloves, safety glasses, dust mask
  • Rubbing alcohol/adhesive remover/standard thinners/wax and grease remover
  • P40 or 40 grit sanding paper
  • P80 or 80 Grit sanding paper
  • P180 or 180 grit sanding paper
  • P320 or 320 grit sanding paper
  • P600 or 600 grit sanding paper
  • P1500 or 1500 grit sanding paper
  • P2000 or 2000 grit sanding paper
  • P3000 or 3000 grit sanding paper
  • P5000 or 5000 grit sanding paper
  • Adhesive body patch/filler backing mesh
  • Fibre glass strand filler/bridging filler/Isopon P40
  • Rust reformer/rust converter
  • Rubberized under body coating
  • Car body filler/cataloy/Isopon P38
  • Glazing putty/Dolphin glaze/Polyester stopper
  • Grey filler primer/high build primer
  • Masking tapes 1″/25mm and 2″/50mm
  • Masking paper
  • Colour matched spray paint
  • Clear coat/lacquer
  • Scratch remover polish

And here is the video:

I think you will agree that is some turnaround!

I Want To Do Some Welding

For various reasons that I won’t go into here, sometimes people might prefer to weld in new metal, if that’s you then check out this video from Restolad. This is a fairly compacted guide to the general process of preparing the rusted area, making a patch, and welding it in.

To then fill and paint the repaired area you can follow the previous video above.

A Mixture Of Both Techniques

If you haven’t yet decided if you need to weld in new metal or is your repair can be done without the need for welding, have a look at this video from Wheeler Dealers where Ed China tackles rust on a few different vehicles, and uses varying techniques depending on the situation:

My Rust Isn’t Bad, It’s Just Bubbles

If you have managed to catch the dreaded rust early enough, and it is small rust bubbles at this stage, then take a look at this video from JohnnyGetsCash. It is very similar to the first video I posted above, but there are some key differences in the techniques which I feel are worth showing you, for example there is no need to use the reinforcing mesh due to the type of repair, and in this technique wet sanding is used on the primer:

And that really is all there is to it, decide if you want to repair the rust using a welder or not, this can depend on if you have a welder (obviously) but also how bad the rust is (see Wheeler Dealers video above), and the time and budget you have for the repair. As usual, this is one of those subjects that I can go deep into and expand on any area, so if you want to know more about any single little bit that I have covered above, please let me know in the comments below.

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