Trunk Patch Panels 101: The Basic Method in 5 Easy Steps

If your classic car or truck has rust, don't worry, you lot're not alone. Body patch panels offer a not bad alternative to replacing the entire body part after rust has invaded a portion of the panel. At that place are many formed patch panels, specific to your vehicle and body area, found in our catalog that take the "risky" part of patch panels out of the equation entirely -- alternatively, we will besides cover how to use sheet metal to repair smaller, flatter areas in this commodity as well.

Difficulty Level: Moderate - Basic Welding & Paw Tool Skill is Required

What You'll Need:

  • Mark
  • Cardboard
  • Angle Grinder
  • Acetone, Possible Media Equalizer
  • Welder
  • Bondo

Here's the Trouble with Bondo

Bondo putty is probably one of the nearly common ways people "repair" harm on a motorcar's body -- while nosotros actually employ Bondo putty in the method beneath, it's merely used to smooth over a surface. You might be tempted to only take hold of a body putty kit from the local auto parts store, slather information technology on, and just call it a day, but we caution against the employ of Bondo for major trunk piece of work.

Body patch panel repair

Equally you can encounter on this 1974 Camaro fender, Bondo can come up off in chunks over time. This Bondo body work was done in a professional body store and the owner noticed the putty pitting about iv years later. He'south now in the process of getting information technology all off then he tin weld in a patch panel instead.

Using Bondo putty to replace an entire rusted area or fill in a dent is very difficult to go "right", it's also a fairly curt term solution. For those unfamiliar with this repair method, you place a piece of mesh over the damaged surface area, make full it in with a putty mixture, and smooth it to conform to the trunk lines of the car.

Even if you get information technology perfect the first time (many don't and cease up having to chisel off the dried chunks and showtime over), the area volition eventually pit and fissure over time. This method, even when perfected, is a bandaid and not a truthful restoration of damage. Patch panels offer a long term fix for metal damage.

Patch Panels Are Easier to Work with Than Y'all'd Call back

Body patch panels seem like a huge task, only y'all'd exist shocked at how basic the process actually is. The method nosotros are about to outline is very simple, although some projects may become more involved -- this method is all-time for smaller areas on floor panels, quarter panels, and fenders.

Step 1: Mark the portion you are replacing with a mark earlier cut. For pre-formed panels, lay the panel down over the area it is intended to supersede, and draw the shape with the marker.

Create a template of the area using cardboard (skip this part if using surface area specific/formed panels). Cut the expanse using an angle grinder, air tools work the best for this portion of cutting.

Perchance the most of import factor leading to the success of this process is fitting the panel in every bit perfectly every bit possible. Be careful not to over cut the area you intend to replace, especially if you lot're using pre-formed panels, and make certain your replacement slice is large enough if using sheet metallic squares.

Annotation: Skip to step iii if using pre-formed panels.

Step 2: When using sail metallic for straight and apartment areas, find a like gauge metallic, trace the template, and cutout with metal sheers or bending grinder (electric or pneumatic is fine).

Manus shape the metal, if you lot tin can't exercise this, buying the pre-formed panel is advised instead.

Stride 3: Prep the metallic (both the torso panel and patch panel) thoroughly at this signal. This may require a simple wipe down with acetone, but you may have to clean it extensively with a media blaster -- don't skip this step, restoration is all about adroitness and quality work.

Footstep 4: Now is when you lot demand to get your welder ready. Lay the metal in identify and spot weld information technology into place.

When welding panels with a MIG welder, you'll want to utilise a 75% argon/25% Co2 mixture.

Lay a long bead of weld instead of small dots considering the metal is and so thin. Brand 1/4" weld spots and grind the welds down with an angle grinder.

Pace five: Afterward grinding the spot welds down, embrace the patch seams with a very thin layer of Bondo putty -- do non cake on the Bondo, information technology is simply meant to smooth and fill the seam! Sand the expanse smoothen by hand and the expanse is at present ready for paint.

There are many other methods when it comes to patch panels, but this is the one we've plant to be the easiest to follow and it works cracking if yous take your time and concentrate on your cuts. It shouldn't have more than a few hours to complete to process and go the auto ready for pigment. Once painted, at that place will exist no signs of rust or damage ever existing on the area.