How To Fix Rust Holes In Your Car The Right Way

Shop for New Auto Parts at 1AAuto.com 1aau.to/c/48/b/rust-repair-panels
In the video, 1A Auto shows how to cut out, patch and finish a rust hole or otherwise damaged body panel. The video is applicable to all steel paneled vehicles.
🔧 List of tools used:
• Flat Blade Screwdriver 1aau.to/oaDI/1AXAA00013
• Cutoff Wheel 1aau.to/oU/1AXAA00254
• Vacuum
• Welder
• Welding Helmet
• Welding Magnet
• Metal Cutters
• Acetone
• Body Filler
• Dust Mask 1aau.to/oj/1AXSS00057
• Gloves 1aau.to/ope/1AXSS00048
• Marker / Writing Utensil
• Painter's Tape
• Paper Towels 1aau.to/orG/1AXSS00035
• Safety Glasses 1aau.to/okb/1AXAA00343
• Sandpaper
• Spray Paint
• Spray Primer
• Bucket
• Cardboard
• Grinder
• Hammer 1aau.to/oCS/1AXAA00091
• Plastic Sheet
• Sanding Block
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Check out our playlist:
Driveway Diagnostics!: • Driveway Diagnostics!
Body Repair - Dents, Dings, Scratches and Rust: • Body Repair - Dents, D...
Tips & Secrets only Mechanics Know: • Tips & Secrets only Me...
For More Info visit us at 1aau.to/h/bzE/
⚠ DISCLAIMER:
While 1A Auto strives to make the information provided in this video as accurate as possible, it makes no claims, promises, or guarantees about the accuracy, completeness or applicability of the content. No information contained in this video shall create any expressed or implied warranty or guarantee of any particular result. All do-it-yourself projects entail some risk. It is the sole responsibility of the viewer to assume this risk. 1A Auto is not responsible or liable for any loss damage (including, but not limited to, actual, consequential, or punitive), liability, claim, or any other injury or cause related to or resulting from any information posted in this video.

[@1AAuto]

√ *Watch the Video* √ *Buy The Part at 1A Auto* 1aau.to/m/Visit-1AAuto √ *Do it Yourself* √ *Save Money*

[@billyralston5291]

THIS GUY IS AWESOME. YOUR FORTUNATE TO HAVE HIM AS AN EMPLOYEE!!

[@cinderswolfhound6874]

Rough up the metal so the weld sticks to it you lame brain you are about to melt the metal together not glue it

[@patcollier4819]

if this guy worked for me he would now be collecting unemployment. hes a backyard mechanic and not a good one at that. how embarrassing to post something as poor as this to the net

[@mback12000]

Friendly Suggestion - spray some weld-through primer on the back of that patch before welding because if not, the entire inside of that patch is raw uncoated steel and will rust through super fast.

[@linmal2242]

You mean he didn't paint the back? What a shonky job by a shonk worker!

[@aaronanderson5197]

@@linmal2242 they dont paint the backsides of panels from the factory

[@nexpro6985]

@@aaronanderson5197 the whole body shell is dipped in anti corrosion treatment before paint at the factory.

[@crforfreedom7407]

Why worry about all that with rust and rust-through on the back-panel? I mean, this wasn't exactly the repair to eliminate rust repair, just pure window-dressing.....

[@terrysullivan9831]

Wouldn't it have made sense to rust- protect any metal accessible before welding on the patch? That includes putting some sort of rust-stop treatment on the inner rust that he found?

[@davidobrien3897]

Love how you are so humble and admit minor mistakes/errors.... very relatable !!! My first autobody effort was a disaster !!!!

[@dwhollrah]

Title should read " Patching rust to get through Inspection."

[@cameronlee4386]

dwhollrah title should read how to fix a rust hole the wrong way so that it eats out the inside of your car without you knowing.

[@ricksanchez8469]

Yeah and how would you do it then?

[@foreverwood1963]

LOL

[@e36fanatics]

for most people there is no point paying whats car worth just to get it trough inspection my dude

[@wizen4937]

ya wtf. def. not the right way with that patch behind it left

[@gordontallent4779]

You always remove the rust underneath and spray it with a rust inhibiter so you will not have it return!

[@crforfreedom7407]

I thought this was an EXCELLENT introductory video for people new to body work!! All the fundamentals are here to get the job done right. WHAT A MAN FOR USING A FLUX-CORE WELDER!!! First time I've seen that! Everyone ALWAYS uses shielded, but if a rookie is borrowing a welder, there is a good chance they might be using flux-core! Excellent! Made the repair just a little tougher but real-world! Nice presentation, overall very well done!!

[@tnoutside]

A bunch of critical comments here. This is not a video for body work professionals. This is for those of us that have an old vehicle with rust, a replacement panel, a grinder, welder and rattle cans. I will be doing a similar repair on my 20 year old Jeep in a couple of days with the same tools. This was a nice prep for someone like me who is a novice and will most certainly screw it up all sorts of ways. And I will incorporate a couple of the suggestions in the comments. Thanks for the video. If my repair looks as good as yours it will be a heck of a lot better than a rust hole. Not for inspection. Just to make me happy.

[@donaldshidal851]

Cant believe you hid that rust underneath without killing it first.

[@hunkydude322]

it's not like it's a half million dollar car.

[@ianbaker9287]

Hunkydude322 regardless!!!

[@kcscustom9759]

Awesome video! I love seeing people taking on projects like this on their own and this video I’m sure will help a lot of people with that👍🏼

[@1AAuto]

+Keith Chapin Thank you for the great reply! We love to empower our customers by showing you how-to perform your own auto repairs while installing our high quality auto parts. Have a great day! 1aauto.com

[@kcscustom9759]

1A Auto Parts: Absolutely, Thank you for the great videos!

[@timmygilbert1371]

I agree !

[@robbflynn4325]

Thanks for this video. Some of us are on a very strict budget and are not restoring classic cars or whatever and just want to keep our old cars on the road to pass inspection!

[@TheCriticalChris]

I like that you used a flux core welder, which are the more affordable welding machines that many DIY novices use.

[@logothaironsides2942]

Looks good. Fortunately car bodies seem to be less rust buckety than before anyway but its always good to see how to do stuff. Would have liked to hear what the settings were on your welder. Mine just has high/low/1 and 2 and the speed dial.

[@user-vb2lq7mr7r]

Thanks Andy, your body repair video is plain and simple. You make it look like anyone,as long as they follow your directions, to do respectable body work. Loved your video,Lester

[@jestertech3790]

Though everyone says rust converter before welding is what you need, I found that spraying the backside of the panel with some fluid film/used motor oil yearly is just as good. (I realise that there aren't always access holes to get behind there)

[@bobbybenn8275]

Great video sir, thanks for sharing. I'm a novice at this and every little bit helps. Keep up the good work

[@1AAuto]

+Bobby Benn Thank you for the great reply. We love to empower our customers by showing you how-to perform your own auto repairs while installing our high quality auto parts. Have a great day! 1aauto.com

[@LiezerZero]

State Inspection for body rust.... LOL, glad that's not my state.

[@just456bc]

Valueless Dollar I think it’s more for holes

[@4dirt2racer0]

yea their all paranoid about exhaust gases getting in...

[@AwakeDude911]

@jmaedl027 jmaedl how many lifes has this saved since this LAW was made? OR how many dollars did this make for the body shops since the law ..now that you can track...

[@gibmelson7628]

Valueless Dollar hoho ! in germany you have to bring your car ans others to a great technique inspektion all two years.inspectors are engineers and find the littlest problem. you pay around 70 $ and max 4 weeks later all problems must be repared. if not the police take the car away.... germania !!

[@zrafferty]

I live in nys only thing that can't have rust holes is the frame

[@brettlyde6338]

Jesus Buford you should have at least sprayed that rust with some Rust Converter after you hit it with a wire brush and covered it up with some primer

[@FiscalRangersFlorida]

I agree - this is like the lazy man's "let's do a cheap job to let the next buyer worry about recurring rust."

[@linmal2242]

Yes, my sentiments exactly, convert that rust and paint it to arrest further grief!

[@panchoperodo4310]

Wow... Not even some ospho ??

[@TonyPablo]

Excellent presentation!! thanks

[@Overzeal0us]

He’s like the Bob Ross of auto repair, I love watching this guy before bed. Knocks me right out.

[@1AAuto]

+Skinner Thanks for checking us out! 1aau.to/m/Shop-1AAuto-c

[@davidcover9591]

what width wire for the flux core and gauge metal did you use for the welds? I've got a fluxcore too but I'm worried about burning through the sheet metal

[@ColinDies]

Man it's such a good video, but you left some pretty important stuff out. It's understandable that you're not restoring the car, but a proper repair is a proper repair no matter how you cut it. Any less is a shortcut. First - once you cut out that piece, finding more rust behind, applying a rust inhibitor would've taken hardly any extra time and would've helped kill the cancer where it was. When sanding the primer, never use your finger tips. Always use a block. Use a soft-ish block if you need to, but even a sponge can sometimes mess it up (you don't want ripples/finger lines in your freshly leveled surface). Once you're done apply the clear, you've got more sanding to do, and if you don't, the finish is going to look dull, and won't feel very smooth to the touch. Apply a few coats of clear (3-5) so you have a little thickness to work with, and block sand that sucker starting at 600, 1000, and then finally 1500 or 2000. Then you polish. THEN you're done. :) It's a good video, but those little things above can help you go from an ok result to a good result (let's face it, Duplicolor's never going to look excellent).

[@1AAuto]

+Colin Dies Thank you for the feedback. 1aauto.com

[@dropkickfetus9710]

@@1AAuto I do my body repair on how people pay ....this repair was lit...thanks

[@thunderbirdizations]

“When grinding the body, make sure none of those sparks hits stuff like the carpet and stuff” 12:29 proceeds to throw a bunch of sparks close range to the tire, and mig weld without covering it up 😂

[@hunkydude322]

just be thankful this guy didn't teach you how real car dealers do it out there in the real world, they take more short cuts than you can count and then some, buy next week your car's paint will be peeling and falling off LOL.

[@tvviewer4500]

@Colin Dies I can tell this guy always showed all the work on his math test.

[@SlightlyDank]

nice vid! we use 2 big putty knives to mix the filler on, my UK teacher says they use cardboard in the UK. that fibre filler is for the really rough jobs but it works great if you wanna fill up a lot in a short time, i some times mix the fiber filler with the regular filler so it gets more flowing when applying (this is an old trick i guess) i was watching this vid cause i was wondering how others did it, might wanna drill hole somewhere unseen in that panel and spray it full undercoating r something like that since the rust was in there than you fill that hole you drilled up with some 2 component body glue/kit (you need to get the job done right aye! ;D)

[@juanalejandro9877]

Great video for us non experts. And, useful comments/suggestions from those more experienced. Overall, extremely helpful video.

[@1AAuto]

+Juan Alejandro Thanks for checking us out!

[@patfromamboy]

@@1AAutoI’d like to repair rust and not have it ever return. 5-10 years goes quickly now that I’m 61. My 66 Chevelle bucket seats need to be rebuilt again. It seems like I just had them restored but it was 40 years ago which is scary. In another 40 years I’ll be 101.

[@ryanphotostudio]

Great video! Perfect amount of information, thanks so much 👌

[@johnsteed265]

This is excellent beginner advice for a great patch. Very easy to follow steps. Thanks for the information!

[@Hereford1642]

Channel - Fitzee's Fabrications - has better advice I think about shaping your metal before you cut out the rust and many examples.

[@jakelancaster4811]

Good video. I have a 1977 gmc jimmy that has like four or so rust spots like the one in this video.

[@rjinnh3933]

Very good vid! No Music/No Drama. Just good Instruction presented in a Cool/Calm and Adult manner. All very normal for A1-Auto.....

[@1AAuto]

+RJinNH Thanks for checking us out! 1aau.to/m/Shop-1AAuto-c

[@twowheelrodeo]

I am going to give it a go, see if I can repair it on the lift. I liked your instructional video and think I can follow these instructions.

[@Mylife-md1zv]

Awesome just what I was looking for simple fix thanks

[@dougbesplug8851]

Very nice video for the average guy I watch the 1A videos a lot just did an Altima video before replaced alternator very helpful

[@raullcalzadilla3541]

Great video, thank you. It's a lot of work for such a little hole but now I know I can do this.

[@1AAuto]

+Raul L Calzadilla Thank you! We love empowering our customers and showing how to perform DIY auto repairs with our high-quality auto parts. 1aau.to/m/Shop-1AAuto-c

[@kabaottoemulsion1869]

Thank you so much! Now I know how to fix small holes! Brilliant!

[@beachwalker2574]

I don't know if you intentionally made mistakes if you did that helps even more ! What not to do !! Great video ! will start mine next month !!!

[@davef4163]

Really nice tutorial video. Very informative, well done!

[@LetricShave]

What gauge metal are you using in this video? Thanks

[@davidg5704]

Sponge idea is great. I bought thin 3m sponge sanding squares but kitchen sponge probably work just as good. Thank for video.

[@1AAuto]

+David Ahders Thank you for the great reply. We love to empower our customers by showing you how-to perform your own auto repairs while installing our high quality auto parts. Have a great day! 1aauto.com

[@johnd.dupree8614]

Great video! I think a rust converter would have done the trick for the inside surface rust. Just suggestion.👍

[@CCROSS5882]

I thought the same thing not sure if the welding would effect it but should be better than not!

[@gthree0239]

Very soon I’m going to tackle an auto body repair. In fact this minivan is going to give me lots of practice. Rusty hood, tailgate, fenders, quarter panels, doors, rockers, inner rockers and probably a few other things. Is it worth fixing? Well, yes and no. It’s practice for me, it’s my kids first set of wheels and it still runs decent so why not. Thanks for the simple explanation.

[@happydays454]

Good to go good job ready for inspection

[@Adamdub612]

How do i set up a appointment with you guys to do my car on a video? I need a few rust problems i need help with its my fanily car/ everythinf car so i would like it to last another 5-7 years. It is a 2008 Cadillac Cts4 awd raven black. Please help 1A auto?

[@ewallacestudent1]

1A Video's actually show the how to do it, love you guys.

[@1AAuto]

+Edward Wallace Thank you! We love empowering our customers and showing how to perform DIY auto repairs with our high-quality auto parts. 1AAuto.com

[@kauaixtremeshorefishing1021]

Excellent… Will I do it different? off course …. Like many others would but thankful for your time and effort

[@ThomasFreundl]

The reason you really use fiberglass is to fill in the voids as it provides water proofing in that area as well, where as body filler doesn't. Also next time consider spraying a weld through zinc primer on the backside to add a little more rust resistance. A very easy way to mask is tape some newspaper over the area and fold it back. The rolled edge allows for a more feathered edge. Also, if it's not a metallic paint you should wet sand the base coat to help eliminate orange peel. Yes you can go further, but some things are easy to take another few minutes to just give it a better looking job in the end.

[@1AAuto]

+Thomas Freundl Thanks for checking us out and providing some additional tips!

[@beowulf39565]

Great video but if I lived in a state that required a rust hole to be fixed before you got an inspection sticker I would just move to another state.

[@ericjkent]

Well it must be nice to be able to just pick up and move

[@ortiztaxi1055]

My rust is way worse on that side on my 04 explorer What would you recommend to repair it? I mostly have a huge hole and also on the driver side passenger door.

[@KenMrKLC]

Pretty good vid... about how I would do it, I would have given a quick scuff and spray with rust convertor on the inner rust however. It killed me to watch it get covered up

[@1AAuto]

+KLC LAWN & LANDSCAPING Thanks for the comments and for watching!

[@bcatz454]

Looks like the many hours of how I'll be spending summers after work and weekends on my old Land Cruiser.

[@1AAuto]

@sc14 thanks for watching!

[@TheWanderer2527]

watch different videos to do it right

[@volvovalor8051]

"You can do >this< but I'm not going to do that." * gets annoyed by not doing a great enough job and does it anyways *

[@hunkydude322]

just take it to the autobody shop and then remortage your home so you can pay the autobody shop for this type of job.

[@crforfreedom7407]

All these great videos is why I order my parts from A1. Excellent customer service too! Love you guys!

[@Imwright720]

A little rust converter would go a long way in slowing the hidden rust. Minimal work for maximum results.

[@davidobrien3897]

You really take the time to explain al the steps well

[@ADESIGNMODELING]

Any suggestion for Primer and Finish Paint , brands , properties, where to buy ?

[@michelatef3292]

GOOD TUTORIAL

[@clydeb7713]

Cheaper and easier way is as follows: Smooth hole. Spay rust converter. Make an aluminum foil ruled up piece to fill hole. Push it in about 1/8 inch. Spray expanding foam. When it drys, cut it with a razor. Push foam in enough to cover with fiberglass body filler. When dry, sand smooth. Paint as needed.

[@dlwhite6537]

Bingo! then inspection and sell.

[@jeepman012]

Nice Job, Thanks for the tip's.

[@1AAuto]

+jeepman012 Thank you for your feedback! We are very proud of our videos, and have more coming out every day.

[@jasonfabian1563]

Thanks for making this video, I have to fix that same area on my 2009 Suburban

[@1AAuto]

+Jason Fabian Thanks for the feedback!

[@uphill248]

Can I use rubbing alcohol if I don’t have acetone?

[@mxr7586]

When I’m welding on my stuff or other ppls it a good thing to block the opening of the door cause those sparks go everywhere like the one that hit the door panel behind you and they can easily go inside and burn seats and carpet.

[@MaNuLaToROfficial]

not to mention the fact that those sparks from welding could totally fawk up your glass windows too.

[@garynokes729]

Nice work, very helpful video.

[@jimcameron4672]

Great instruction video

[@chumaluf]

thanks Dude Awsome Job

[@matthewgutman7167]

I have an old 81 rabbit pickup I want to restore, what was that sheet of metal you used? Do I need a specific metal? Thanks

[@mikeaze423]

If your asking have someone else do it

[@rotfan77]

Great job. I need to do this on one of my cars, but I never thought I could actually do it,

[@gehringer37]

I love this guys personality!!! Awesome!!!

[@1AAuto]

+Mikes Garage Thanks for the feedback!

[@tomeighty]

Great video, thanks for taking the time to show the work.

[@seove1]

What is the gauge of the sheet metal?

[@donaldmorrison5289]

Great job very nice patient explanation.

[@wallyknapp7023]

Good video but i'm curious. What rust belt state are you in that has a no hole policy?

[@g.pearson4726]

Great teacher ‼

[@Thunderpalm510]

Nice video, thanks for sharing.

[@1AAuto]

+Ken Bloom Thank you for the feedback and for watching!

[@lowhertzhighspl]

Excellent video

[@justauser]

My province doesn't have regular inspections but it has inspections on transfer (when you sell the vehicle), so usually when cars get too rusty to sell they just drive them until the wheels fall off.. sometimes literally!

[@nikaiman8068]

Tq for sharing tips and tricks bro

[@CA-pv5ie]

Super helpful - thanks for the video

[@1AAuto]

+C A 0297 Thanks for checking us out! 1AAuto.com

[@MrBillmedhurst]

Great video! I've watched many body repair videos but learned more from this one. Thanks!

[@1AAuto]

+Harpo Thanks for checking us out. Shop here for high quality auto parts: 1aau.to/m/Shop-1AAuto-c

[@BigPhatAlbert]

Thanks... I'm having a hard time not blowing through with flux core . It's like I have to heat it before it will take the heat, but then my gap is too big . Putting a piece of brass behind while I weld helps but I can't always access the back.... you think YOURE welds were ugly lol

[@styga1969]

Question. What gage metal did you use ? Nice job. 👍

[@chuysz06]

Nice job!

[@blackenigma1054]

Good job!👍🏿

[@davidobrien3897]

GREAT CONTENT AND INSTRUCTION

[@paulcohen142]

Did he really say you gotta rough up the surface so the weld sticks to it ? 😂

[@krxnkii]

Paul Cohen he also said he knows how to weld, just not professionally. So probably a mistake on his part

[@ryanmcgowan3061]

He's really cleaning off surface contaminants, which yeah, helps it stick. I would have used a fine grain sandpaper instead.

[@paulcohen142]

Ryan McGowan you do understand that welding is melting the metal? Its not sticking to it, clean it sure it will help prevent porosity but it’s not gonna make a difference to that sheet metal you would have to be a terrible welder to not get peno...

[@NSB25445]

@@paulcohen142 It does not melt the metal, it just gets it hot enough to stick to the molten metal coming from the electrode. If it was melting the metal, you wouldn't need flux.

[@NSB25445]

@@paulcohen142 to further prove my point that welding does not mean melting the metal, look up forge welding on Google.

[@peteriko123]

sir is that true if welding process leave hole and we fill it with filler, there is a potential for water going in to the hole behind the welding and make the new corossion again? sorry for my bad english, im indonesian. thanks

[@1AAuto]

+Piterz Xiao Thanks for watching! This video details a very basic patch job so you can get your vehicle to pass safety inspection, and it is mentioned a couple of times. You would want to repair the rust behind the panel if you want a longer lasting repair! 1aauto.com

[@henrysmith8012]

Eastwood welding magnets really help. Make 2 tacks and then cool with compressed air.

[@dlwhite6537]

Thanks for this. My F-150 has a hole in the same spot. Now it's like I've seen my buddy do it first.

[@danielsmit11]

I'm still wondering what wacky State fails an inspection over a non structural rust spot like that. Sure it were in the frame or floor pan that'd be a different story but that wasn't the case

[@patriotswillsurvive1893]

Nice work. Body work is such a pain but so satisfying.

[@1AAuto]

Thanks for checking us out. 1aauto.com +michael shepke

[@beyondandback]

I have a swollen radiator hose from bottom of radiator to the motor. I added antifreeze concentrate and then tested to make sure no boil. New radiator cap. Light comes on parts store said ecm not communicating check fuses. All fuses good I guess. I feel like the temperature gauge on dash is not working. Because sometimes when I turn key off the temp gauge four up. Idk what to do. Single 60 yr old no income no help. Please and thank you God blessj

[@buchanansleeve7427]

Great Job Bud !

[@1AAuto]

+Buchanan Sleeve Thanks for checking us out! 1AAuto.com

[@newsnowtwincities9331]

It's important to note that when you disconnect the battery on late model vehicles, you may need to enter an alarm system code to regain full functionality. If you don't already have that code, go to a dealership and give them the VIN number.

[@roncolpo5056]

Nice job

[@billymarques8168]

Great job!!

[@billhill839]

Growing up in Pa as a teenager I had to get my car inspected every six months. What a pain in the ass. I must of had a hundred pounds of bondo on my cars then. One of the nice things about moving to Ohio in my twenties was no more inspections.

[@linmal2242]

How slack are they in Ohio then? Yes, not near the coast, but.....

[@blucow6677]

what gauge is that sheet metal you used 6:31

[@Mentalpatiencevapes]

Thanks again guys. Awesome videos

[@1AAuto]

+MP Thanks for the feedback!

[@TedTremendous]

You mentioned something called a DA in the video for sanding... what is that tool for sanding you use? can you use an angle grinder or just needs to be a sander?

[@racheat]

Dual Action sander...used after priming to save time and leave irregular pattern.

[@knottreel]

Amazing job. I didn't expect it to match so well.

[@1AAuto]

Thanks for the feedback! +Knott Reel

[@bobvel7760]

Wire wheel as much as you can on inside, then rust converter. I would have also put tacks from the top down while introducing the slight curve required.

[@kevinhumphrey932]

What about all the sparks from the welder that's landing on the door panel and seats

[@jagers4xford471]

That interior rust under the patch needed to be sprayed with rust reformer. Once the rust has been chemically treated seal the area with a sealer such as Mad Dog to keep any moister out and rust from reforming. While you have it open, you might as well.. Not to do that is like changing a clutch and not bother to replace the throw out bearing.

[@1AAuto]

+Jager's 4xFORD Thanks for the tip! We'll pass this info along to our production team.

[@waynehoffman3407]

What gauge metal are you using in this video...???

[@sdfsdfsdfsdsdfsf8468]

Can you use revits