How to Repair a Rust Holes and Weld Body Panels

Cleco Fasteners amzn.to/3JLltb9
Flange tool amzn.to/3qXAf5U
Canadian Link amzn.to/3f3G9Nw
todays video is the DIY rust repair on my 2006 f150 pickup truck. The drivers side front lower box has rusted out leaving a huge hole to repair. I picked up a patch panel from Rockauto which made this job way easier. The first job is to cut out all the rust and remember the rust extends further than the hole or area itself. I then fitted up my patch panel to weld in place. I used cleco fastener kit to hold the patch panel into place while I used my esab rebel welder to fix the repair
DISCLAIMER: Due to factors out of the control of Bullshitkorner and Bsk Garage, we cannot guarantee against improper use or unauthorized modifications of this information. Bullshitkorner and Bsk garage assumes no liability or responsibility for property damages or injury incurred as a result of any information contained in this video and all other videos produced by Bullshitkorner and Bsk Garage. Use this information at your own risk. Bullshitkorner and Bsk Garage recommends safe practices when working on vehicles and/or with tools seen in this video. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not Bullshitkorner and Bsk Garage Be safe! This video and description contain affiliate links, which means that if you click on one of the product links, we receive a small commission. This helps support the channel and allows us to continue to make videos like this. Thank you for the support!

[@TestDontguess]

Watch a more Trickier Rust Repair video here kzbin.info/www/bejne/fYq3o6yCrpVjnbc

[@diane2193]

Excellent job!!!! Years ago I used sheet metal and pop rivets on a quarter panel. Lol

[@gunner8822]

What were those things called that held the panel together you drilled the holes and put them in there

[@user-co8un6lx3t]

Братан, за чем такие большие швы ?

[@spencerrivera2692]

BSK Garage help me out for my car what should I do I only have little Rust what to do?

[@lesglover6515]

@@gunner8822 those are called cleco fasteners.

[@spinb]

Very good video. Thanks for not adding annoying music!

[@MrSmartass89]

Excellent job, sir. You are first-class. Your video was awesome. Short, sweet, and to the point. No BS and no time wasted.

[@TheWwong]

Well done, those Sears newspaper ads could be collector's items very soon.

[@TestDontguess]

They sure went downhill from the days of buying a diy house kit in the early turn of the century

[@bayoupirate3808]

Thank You. Presented very well and I walked away knowing more than I did before. Again, Thank You.

[@learndaanswers3066]

The new piece of metal was cut to perfection. Can you do a show on how to achieve bends and curves?

[@Syncopia]

It was a specifically made patch panel for that make and model.

[@learndaanswers3066]

@@Syncopia thanks

[@harmanbrar591]

Where are we get those panels

[@onthatdove]

Man, I've watched a handful of your vids over the years when you did various work on your personal TJ. I just stumbled upon this video and had to watch another video under BSK Garage instead of your "previous" channel. I have to say, I am speechless at what an enormous improvement I see in your demeanor and choice of vocab. Now, I'm more encouraged to share your videos with my young 12yr old son who is building his own 1988 B2200 which requires numerous body panel weld patches and paint. I've learned a good bit from you years ago with the Jeep and now my son can also. Thank you! Keep up the clean and great informative teaching vids! You are investing in the next generation of DIY mechanics.

[@TestDontguess]

This channel doesn’t have any swearing or beer drinking. The other channel is more real life. BSK Garage was created for those who wanted a clean video

[@yr4137]

You can be impressed by your job, man, it is perfect. Thank you for the sharing.

[@SA-lr1sf]

The before and after is just amazing!

[@JacksonGarage]

This is great, thanks for sharing. I'm busy with a Beetle lid as my first ever rust repair.

[@ShainAndrews]

Not bad. Only thing I would add is automotive seam sealer on the inside flange. Otherwise it becomes a pocket to start the whole process over in short order.

[@vitopasquino3236]

Honda Ridgeline video

[@ab-qh6ip]

been there done that even with seam sealer, lasted about two years then rusted again.

[@mback12000]

That's why you do butt welds, not lap joints. Water is just going to sit in that groove from the inside where it's raw metal from welding. The rust will return only now faster and higher in the fender.

[@jonminnella4157]

I've never met a body man yet that can guarantee that rust won't come back

[@rodneyspencer2408]

That's why it's a better idea to flange the metal on the car instead of the replacement panel. Then you can install the new panel on top of the old metal. No pocket for water to pool in

[@XXX-qk2cq]

Great job on the panel repair! I have used that pro 3M rocker guard on many used cars here in New England. In a commercial shop it cuts out many finishing steps!!!!! And lasts for ever!!!

[@Mr.Riffian]

Great video! One tip for holding the newspaper in place: use little magnets.

[@hawkdsl]

Great job, and nice how to. Ford owners need this skill more then any other brand.

[@thatmarred_mustang]

Idk where your from, but where I am in the rust belt, Chevrolets are the ones with the issues. Even the Chevy owns admit that much 😂

[@hawkdsl]

@@thatmarred_mustang No Chevy owner could, or would "admit" any such thing. It is literally impossible. Don't argue with science, and the laws of physics. It is known.

[@thatmarred_mustang]

@@hawkdsl 😂😂😂 alright man, whatever you say 🤣🤣

[@bobm7325]

It's said on a quiet night you can hear a Ford rusting away but it could be my Chevy unfortunately.

[@hawkdsl]

@@bobm7325 All kidding aside.. anything made with steel will rust. Proper care always beats rust. Too many people only care about the side that faces up. Unfortunately, we live in a 3 dimensional world. My 89 K2500 Chevy has 200k on her, and even after 30 years, has never had rust on it. I paid 15k for it new. At the time, that was like buying a house for me. It didn't make sense to me to let my money rust away... So I was pretty fanatical about it's upkeep.

[@fixinggrace]

Those are called Cleco fasteners you’re using to hold those panels together. Really handy when you’ve got to do a lot of welding sheet metal on cars and trucks.

[@allamakee1397]

Very informative. Your production value is excellant, Thank for the upload. Regards

[@MikeKiddieCoachbuilder]

Nice repair. The only thing I would do different is to joggle the truck side panel instead of the patch panel. Joggling the patch panel leaves the join open to the top which will allow water to run down into the join. Joggling the existing side panel leaves the join open to the bottom allowing water to go past and not into the join. Thanks for the video, its nice to see a proper repair for a change.

[@adamh1889]

That welding shield is badass

[@robertanon1910]

one of the best vids I've seen, so much to see, and seeing is believing, no long dissertations, great job. Even the quick inside spray with zinc paint, gotta look that up.

[@TestDontguess]

Thanks for watching

[@quadsportsuzuki]

simple ,but very well explained video

[@adanacro]

looks good! I used Raptor bedliner/undercoat/rockguard to redo the top of my 88 Bronco. Looks better than factory! and easy to touch up if needed. Always enjoy your videos, thanks for doing them!

[@tommytrucker11]

Thanks for no bad language and you can use chassis saver on inside of panel and under truck

[@backyardbuilttrucks1]

80 grit flap disc works great to knock down welds , Bondo over bare metal I always seal the metal first . Nice job looks good .

[@jimbrown1390]

Very nice work friend , that bed liner coating looks rugged and cool at the same time

[@mdogg1604]

Nice job, but I would have flanged the truck panel rather than the patch to avoid any chance of the back side flange protruding outward where it could collect moisture.

[@Bdady74]

One of your best videos! Thanks for posting!

[@richardhatt6541]

I like the welding hood.

[@WildWestGarage]

Looks good, only problem I have with this repair is the way the panels were overlapped, essentially creating a gutter for moisture to get trapped in.

[@daxinventor3542]

Perfect. Good job! I especially like the bed liner paint that you used in the end. Look really great.

[@CoBrAChiCKeN948]

Pretty sure it was raptor liner he was spraying

[@dmitrykondratev7425]

Nice work!!! From Russia with love !!! Like👍

[@ThePlowGuys]

Well, you made that look easy enough Jerry.

[@philipnewton7524]

You have made a lovely job of that pal great video Phil in the uk

[@thehappytexan]

Nice work man. Looks like a quality repair for much less coin than a body shop.

[@SuperFkv]

Beautiful welding

[@scottryan9845]

Excellent job

[@diavolorosso69]

Great job- I've had to scrap 2 cars so far only 'cause of rust and it ticks me off to no end to junk a car without major mechanical issues....

[@TestDontguess]

Depending where you live yes, the rust can’t rot your vehicle before it’s worn out

[@jeremiahhebner8593]

Looks good, bout to do some panel work on my jeep so definitely shed some light on how to weld, thanks

[@Kyle-nq5si]

Fine job. Pro status.

[@GoldenSim27]

and dont forget to paint the inside part were it was welded !! or shoot with oil by a hole if not accessible ;) nice video

[@johnaleman6456]

Looking real good now, good job.

[@frontlinemedia4270]

Flange the body panel, now you have a way for water to run into the panel by flanging the panel instead of the body

[@mj007nz]

Thought the same thing.

[@jeremypoole2054]

Looks awesome good job man,I do alot of welding myself I just got into body panels ,I love it

[@dotsanmpendi8785]

Your helmet looks awesome

[@jeffruebens8355]

Afterwards, add Fluid Film spray from a Lowes store or online to the steel surfaces, including inside drain holes for inner door cavities, maybe drilling extra lower drain holes with spray foam seals after you are done, to be redone every fall. I also like the ceramic brake caliper paint from an Advance auto parts store to block dirt and salt spray. I use the Fluid Film spray for motorcycle chains, jacket zippers and inside locks and ignition switches. Do not use it for door gaskets- use silicone spray or Mothers VLR spray instead for door gaskets. See the Project Farm KZbin videos for maintenance tips.

[@glendehaan8010]

Very well presented video. Thank you!

[@aflaz171]

I haven't seen a vehicle rust like that since the mid 80s in my country.

[@williamdavidson9009]

It seems that pick-up trucks since about 2000 are rusting worse than some of the older ones. Look at how that area has lots of layers of metal that trap salt and dirt causing rust. It almost seems that they are designed to rust.

[@MandrakeRoots]

Damn! Wish I would have seen this video before cutting out my corners... first time bodyworker, never thought I would ever need a crimp tool...guess its open butt weld for me...damn!

[@jonathanyates5198]

Butt weld is better. It will last way longer

[@debrastutts204]

Great work!

[@loganlopez3185]

I can't wait to try a repair like this for myself. Actually I want to try my everlast welder in pulse mig mode. That should be fun.

[@thegeneral3094]

That would be awesome

[@kuhtalainenkullinlutkuttaj3136]

Very nice video, and a clean end result.

[@jameslindbloom2615]

Nice demo ....

[@josephwhite9992]

I need to weld some panels with my everlast welder so thanks for this video.

[@rodneyclements4386]

Nice work! A great refresher as well! Thanks

[@researchandbuild1751]

Just a note, i dont think you should use ad flyers for masking, paint goes right through them. Get some masking paper its cheap and every home store has it

[@TestDontguess]

Just a note....... wrong used them for years and never had a issue

[@bobm7325]

Because the ads are small it goes around easily but if taped well enough it's fine. I've never had a problem.

[@stilllearning6035]

Very nice job

[@64airbus]

drill the bottom into a small hole where the rust guard can be sprayed into the inside.... the hole can be filled with car body putty

[@TestDontguess]

Why when you can just spray the panel from the opposite side 🤔🤔

[@georgespangler1517]

Nice job,,I'm building a 46 pickup, I'm going to leave it bare metal and clear coat it, only have a few repairs, but I have to be precise to have the look I want.

[@tarmac245]

A good job. Thanks for quality video.

[@COM70]

Before you weld on a vehicle make sure you leave your battery connected and use a surge protector connected across the terminals.

[@dreydonstanford8376]

Nice lid

[@dannyboy8330]

i use compressed air to cool the welds down, no time wasted :))

[@TestDontguess]

I’ve used that method quite a bit as well

[@kevinmulchansingh556]

Credit where its due, nice job!

[@geoffhalstead1811]

Why not trim the patch panel first and use it to scribe on the car?

[@danielwhitman763]

Great video ... But how long does it take to get the overspray off everything ?

[@johnmav8309]

Thank you! Very good and educational!

[@jamesjohnson9668]

Like ur helmet dude

[@ODGColornChrome]

One thing to watch for. If your weld is just no acting right you may need to secure the patch without magnets. Sometimes the magnetic field will interfere with the arc.

[@jonathanyates5198]

No magnet was used

[@tahirm.1206]

По окончании полости залить отработанным маслом, потом когда стечёт, нагреть резину-битумную мастику и туда же залить.

[@user-dn1wp2kx4d]

Гамырщики

[@tahirm.1206]

@@user-dn1wp2kx4d судьба такая. ))

[@David-wy9jl]

Nice job

[@grahamball364]

Nice work see you next time .

[@aquilesgarcia590]

Te quedó soñado perro felicitaciones 👏👏👏

[@nhamtuantd]

Good video sharing. thank you very much

[@malcolmnicholls2893]

Nice practical job.

[@Syncopia]

Looks mint brother

[@gastonmarcelo3648]

Good Job!

[@TheMultisportGeek]

Nice work man.

[@lifeRobrandom]

Good job wouldn't be putting zinc coating where I'm welding fumes are poisonous

[@ABTOPECTABPATOP]

Привет, не знаю как вас зовут.Очень интерестное видео. Вопрос ,что за заклепки что вы прижимаете латку ? Можно ссылку ?

[@steveguest8028]

Great repair video 👍

[@bradfordjusting9302]

Thank you for informative well drawed video

[@scotto6120]

Nice job! Did you spray the backside of the patch panel with the same black rocker paint or just left it with the zinc coating?

[@mback12000]

Doesn't matter, water will sit in that lap joint where paint cannot reach and rust will come back. Lot of nice hard work here but making a butt joint instead of that long moisture trap would make all the difference in longevity.

[@SkaterStimm]

@@mback12000 Even a butt joint would have left exposed welds on the back of the panel. Regardless of the method used you would need to shoot some oil or paint or something on the back side. For rockers lap joints are way way stronger, but each have their pros and cons. I would have gone with the Butt weld too.

[@skliros9235]

Best thing to do is prevent the rust from happening in the first place. Spray fluid film or any kind of spray grease inside all the lower panel edges, inside the wheel arch, inside and outside door bottoms, seams.... basically anywhere prone for rust. You want Oily metal which won't rust.

[@derpypedro9589]

skliros or just wash your cars undercarriage regularly

[@skliros9235]

@@derpypedro9589 rust starts in the seams/folds of the metal. How would you wash that? And better yet, how would you dry that?

[@63ch31]

@@skliros9235 you get oil in there so that it displaces the water.

[@tomple]

I like those painting on the mask

[@CharlieMoDank14]

Looks good.

[@marlonharris2081]

Turned out nice

[@chucklucas8747]

Your welding could use a little work but it got the job done

[@Mikefngarage]

good job but it seems like a repair that would have been done on a classic car not a daily driver. My only concerns are the backside of the metal is not painted and why did you butt weld in the inner panel. I would have put in an overlaping patch on the inner panel then painted the backside before installing it. Possibly even used panel adhesive and an overlay on the outer panel on a regular car repair like that. would probably have less chances of rusting out again in the same spot.

[@CHIBA280CRV]

Fantastic job sir thank you

[@jimcameron4672]

Excellent

[@elguardiandeltesoro]

hola , buen video!! deberias usar protección auditiva al utiizar herramientas eléctricas o neumáticas

[@user-my5od3kk7f]

Молодец - отлично получилось...

[@nick_romeo]

princess auto box love it

[@sergjay7993]

beautiful tire

[@1979ascona]

You did everything good, but why did you not change all of the inner panel, as there was rust on it? Rust will, returnera there, Thomas, car.welder as you are 😎

[@angrypants7619]

Never disconnected a battery, and never had a problem

[@markanthony3275]

Clecos are a waste of time for bodywork...the more holes you make , the more you have to fill with weld... the more you weld , the more warpage you get, the more warpage you get the more filler you need, and the more chance of rust returning. Spend most of your time on the metal...making sure the patch fits perfectly...then everything else becomes easier.

[@drugsguys914]

what tool do you use to hold the iron panel on the body of the car sir

[@Max-kw4px]

What's the deal with the zinc paint? Is that essentially a self etching primer? What type of paint do you use? I'm just learning about all this body work stuff and seems like there is so much cheap and crappy paint out there - really struggling to understand/find durable products. So much work to prep, would hate to have to redo it after 1-2 years with shitty paint that rusts through!

[@dusa1122]

Nice when you use a gravel guard like that minimal bodywork

[@markwest7258]

I'm wondering, does polarity of your welder cause any danger to the car's electronics? I'll be stick welding using an inverter and was planning on Electrode Negative. Is that still safe for vehicle electronics if I disconnect BOTH battery terminals? I plan on using a keep alive battery plugged direct into the OBD2 port.