How To Repair Sheet Metal

The welding process actually adds new steel to the thin steel and can result in a repaired spot that is stronger than the original metal.

How to repair sheet metal. Using lineman s pliers the plug is cut to shape slowly snipping into a circle. Mark the dimensions and shape using a metal. How to do metal repair without welding step 1. You can then cut.

How to repair sheet metal 1. Here is a tutorial how to video that show. Don your safety glasses face shield and leather work gloves. I then used the templates to trace out the patch panels on some sheet metal.

Whether you re fixing a dent rust hail etc. I used a piece of pvc pipe a vice mount miniature metal break and body hammer kit. The complexity of welding increases as the thickness of the material decreases. The sheet metal patch should overlap onto the metal panel at least 2 inches past the edges of the damaged area.

Cut the sheet metal along the scribed lines using metal shears or a handheld rotary cutting tool equipped with a. After the sheet metal patch has been cut and fit to size round the corners of the patch with a file or emery cloth to prevent any sharp corners from becoming a catching spot for snow or ice. When i got to where it fit i pressed it into the hole using the same pliers. Cut the chosen sheet metal to a size that matches the area to be patched.

Lower your face shield and thoroughly clean the metal. After slicing the patches out with a cutoff wheel next came the bending hammer and dolly session until the patches matched the holes and fit snug and flush into the flanged seat. Make sure not to cut through the underlying metal. Attach the wire wheel to the 4 inch grinder.

Weld the most permanent repair to a hole in sheet metal is to weld the hole shut. The first thing to do is carefully cut away the rusted out area. For thicker sheet metal an old copper penny might be a quick source of material. Lay the removed section on a piece of fresh steel and trace the outline.

Place the repair sheet metal. Measure a piece of sheet metal for the repair with a measuring tape.