Extreme Rust Hole Repair w/ Homemade Patch Panel - Part 1
This video on extreme rust hole repair shows how to fix almost any rust hole with a few tools and a homemade sheet metal patch. Tools, materials and Lakeside Merch below:
🔥 Body Hammer - Martin Sprocket & Gear Tools MRT158G General Purpose Pick Hammer with Hickory Handle
🔥 Tin Snips - WISS Aviation Snips left, right and straight
🔥 Electric Metal Sheers - www.harborfreight.com/5-amp-1...
🔥 Metal Hole Saw Kit - MATCO - www.matcotools.com/catalog/pr...
🔥 Welding Clamps - Irwin Vise Grip C Clamp
🔥 Welder - ARCCAPTAIN MIG 200 - • ARCCAPTAIN MIG200 6 in...
🔥 Comma Dolly - Martin Tools Light Weight Wedge Dolly (MRT1065)
🔥 Spray Undercoating - Auto Body Master # 7668 Rubberized Undercoating
🔥 Welding Helmet - YESWELDER - Atomic Dice Welding Helmet - • Atomic Dice x YesWelde...
🔥 Sheet Metal Nibbler - Northern Tool (No Longer Available)
🔥 Round Dolly - Hand Made on Lathe
🔥 2nd Body Hammer - Martin Cross Chisel Hammer 153G
🔥 Lakeside Discord (Your Projects & More) - / discord
🔥 Lakeside Merch & Apparel - brothersdesignsmi.com/shop-al...
🔥 Lakeside Autobody - / @lakesideautobody
Thanks for doing these and showing the actual work being done in real time..
You're welcome Edward - have a good weekend :)
Good JOB....👌🏻👌🏻
You think he did this in 20 minutes?
Hey Jerry, I really enjoy and appreciate you sharing your skills. Saving another Michigan rust bucket. Looking forward to part two. Thanks.
Thanks for the kind words Paul - glad you enjoyed it 😊
Rust repair...something I get stuck with quite a lot. So good to see another video on the subject👍
I appreciate your + comments all the time BBG - have a nice weekend :)
@@LakesideAutobodyI know nothing but I do have a question just seen different tuber show me for first time a flange tool. Would you consider using a overlay versus a butt splice for the old to new sheet metal.
@@JohnnyAtlas You can used a flange tool if you prefer but in a high volume body shop there's really no time to mess with it. Cut the rust out, cut a patch, weld, knock it down, fill. That's it - every time - every hole. You can't always use the flange tool - wheel well lips, rockers, sharp bodylines and corners, around tail lights.... so the thinking is why use it anywhere - if a simple lap joint works. Here's a good video that can clear things up a bit - kzhead.info/sun/fa2Cn9KChoioomw/bejne.html
@@LakesideAutobody you are a great teacher thanks for the link totally understand why now.
@@JohnnyAtlas You're welcome - glad it helped. Thanks for the kind words :)
You are the master Jerry - of body work...and film making! SO helpful, thank you!
Thanks CA - I appreciate your support - always good to hear from you my friend :)
That's a great job! I look forward to watching the finish video. Thanks for sharing
I will finish it too - just got to get back to it. Been busy with other jobs lately :)
Awesome job! It’s nice to see someone still patchin’ em up.
Not too much of that going on in shops today for sure :)
Nice to see you do a rust repair after a while jerry. Look forward to part 2
Thanks SS - glad you enjoy them. Have a good weekend :)
Thank you. I followed your videos exclusively to repair a corner of the passenger door on my 2008 Highlander. Now it’ll pass inspection here in Pa. 😊
Awesome - love to hear things like that :)
Amazing work , a true craftsman. Thank you for sharing your secrets to us DIY folks who like to do things for ourselves
Glad you enjoyed it ODD - thanks for watching :)
Holy crap. That's some serious skill brother 😊. Great job and thanks for the video.
Thanks TJ - have a good weekend :)
Got over 350K miles out of my old 1990 Bonneville before rust did it in. Cool to see rust fixed now and then. Wish I had done that with mine in the past before it got too bad.
I love your videos!! You take the intimidation out of body work. You're like the Da Vinci of body work!!
😊 thanks - I appreciate your kindness.
That was very good job man , please make more videos like those
I'll keep them coming CL - have a good weekend :)
As always, your work is amazing.
Thanks Coolcat - I appreciate that. Have a great week :)
Great job fitting your own patch in. You make it look simple. I better start saving my Wheaties Boxes
Thanks RG - always good to hear your + comments :)
This is an amazing video!!!!! Truly skilled and thanks for sharing your experience
I appreciate the kind words my friend - enjoy the week :)
Awesome work, you are a Artist with sheet metal. Enjoyed this very much and learned alot too.
Thanks for the kind words MJAC - have a nice weekend :)
Great job Jerry this is my favorite metal work
Much appreciated Louis - have a great weekend :)
Simple and effective, excellent 👍
Thanks! 👍 HKR
Thanks for the video Jerry. Saving another rust-bucket one patch at a time! Randy
Yes - thanks for watching Randy :)
These videos are brilliant. I'm rebuilding my Dodge Dakota. Got all the mechanical stuff done, now it's time to rebuild the body. I got a box from the dump that's in better shape than mine, but it still needs wheel arches and rockers, and at least one cab corner. I have all the new patch panels. Just need to learn to weld first, ha ha. These videos give me hope.
You can do this my friend - just ask a bunch of ?s - any time. I get to them 1-2 times a day :)
rebuilding my Dakota
I sure enjoy watching a real Pro work. I've gained an incredible amount of knowledge from watching your videos. So much so that I tackled my son's rust bucket '02 Sierra project and it actually came out ok! It's a Michigan truck and the rust was rusted. I can't thank you enough for creating and posting these videos! 💯💪🤙
Thanks Doug - I love hearing stories like that - awesome 👍 Each job you do, you get better so... If that looked decent just think how they'll look down the road. Keep me posted on future projects my friend 😊
@Lakeside Autobody , also curious what gauge sheet metal you used on this repair? Thx!
@@dwreed63 20 gauge (~.035") You can use 22 gauge too (~.030")
@Lakeside Autobody , I think I had to use 18 ga on the truck, it was what ALRO steel had available at the time. It was a bit stiff 🤓 Thank you for the response
@@dwreed63 You can rest easy knowing it'll last longer 😊
I have watched several of your videos and though I’m experienced doing rust repair in my home garage on my projects, especially on trucks, I still pick up new ideas and techniques from you. Also like some of your dent removal techniques. One thing I started doing after watching your videos is using a cheese grader. I’ll keep watching and learning!
The cheese grater can really make a difference in speed and getting the dent straight. Thanks for watching Randy - enjoy the rest of the week :)
Thank you Jerry for another great how to step by step vidio. Take care.
You take care too Mike - nice to hear from you as always :)
Awesome work as per usual
Thanks JRM - have a good week :)
You sure do nice work. And you are a good teacher
Thanks Mike - have a good weekend my friend :)
Another great video Jerry. I hope you and your family are doing well.
Hi Bluesman - thanks for checking in - good to hear from you my friend. If you're ever back this way stop in whenever :)
Looks great
Thanks my friend - enjoy the rest of the week :)
Excellent video! Looks like all too familiar Michigan rust. Take care, looking forward to more.
Thanks 👍. Have a good weekend William 👍😊
Good video, I keep singing in my head "love hurts" watching it
Big Jerry got some of the best body work training videos on youtube . From a Pro Tech🙏🙏💪💪💪
Thanks AEW1 - that's nice to hear coming from someone who works in the field. I really appreciate the support 👍😊
Man those side cut plyers are Awesome 😃
Great video. Enjoyable watch.
Thanks C636 - enjoy the rest of the week :)
Hi thank you for sharing your knowledge fixing rusty cars llike a real hard worker man,excellent job,appreciate it.God Bless 🙏👍👌
Thanks for the kind words Hector - God Bless you too my friend 😊✌
now that's a craftsmen a lost art , I enjoyed this very much sir respect for your talent .
Thanks Old Biker - what's your favorite road bike?
@@LakesideAutobody it was a 1994 Harley heritage my son rides it now , my other son rides my 1999 standard bat wing , both bikes have 130 k miles on them I don't ride any more legs' are to week and I'm 70 years old , but I still restore cars and trucks. thanks for asking.
@@oldbiker9739 I love to hear peoples stories. Thanks for sharing ✌
We use to make our own patches all the time. The patch panels you buy are so expensive now and don't fit anyway. Good tin smithing
👍✌😊
I’m going to try teaching myself how to do so extensive rust repair on an old minivan. I’ll probably end up buying some premade pieces but some will be freehand. Thanks for posting these vids and giving us a reference to turn to in a jam.
That's great to hear. Ask ?s if needed. Thanks for watching and you're welcome 👍😊🏈
Awesome work, sir.
Thanks and thanks for watching :)
Great video! A lot to learn here
Great video Jerry you're a metal magician!
Thank UPK - hope you're catching up on all the work you had over there a while back :)
@@LakesideAutobody it’s rough Jerry but I’m catching up, this weather is trying to get nice and I want to enjoy it this year!
@@UndergroundPaintKing Got to take time to enjoy it for sure :)
@@LakesideAutobody yes sir I agree!
I am impressed!
Thanks for watching Rory :)
Great job Jerry, you almost make it look easy. I love these metal working videos. Have a great weekend
Thanks Bruce - you too. I appreciate you comments :)
Nicely done Bud!!☻
Thanks RK - have a nice weekend :)
Great video Jerry. Thank you. AL
Very welcome Al - have a good weekend :)
This customer really loves his truck
Great video man🤘🤘
Thanks James 🛠👍✌
Thank's very help full.Good Job.
You're welcome Mike :)
The magic hands of an expert with years of experience. This is a genius at work.
Thanks for the kind words Bruce :)
Other great job. Keep up the good work and have a great weekend
Thanks Brad - appreciate it 😊
Wow, you're an exceptional welder. And wow, that's some amazing body repair.
Thanks Charles - I appreciate the support :)
So, my truck is doing the same thing living in salt-road Ohio. But I can't do that kind of metal work. Haven't quite figured out what to do yet. Not sure if it's inappropriate for me to ask about how much (roughly) it costs to have a body technician do a job like that. But either way, that's some really good work.
@@charlesbarr3561 Thanks Charles. Odds are you probably won't find anyone to do it. They'd probably suggest a new bed or box side at least. A box side is probably around $700 so I'm thinkin' a ballpark estimate might be $2000 to have someone replace the box side. Depends a lot on the individual shop. It's very expensive today because of cost of paint, materials, labor, etc. Hope that helps a bit :)
@@LakesideAutobody that's exactly what I was thinking. I don't think any of the body shops I know would pick up a job like that. I should probably start looking for a bed side, the bed itself has been discontinued for a while. I appreciate the honest response. Can't wait to watch the next video. 👍
great video, helped me out a lot with my rust bucket haha
👍😊
Your a BEAST, GOD BLESS your talent
Thanks Antonio - glad you liked the video :)
Just when I think I can't learn anything more from you- -you go ahead and educate me more and more and more I learn and just get dumbfounded amazed with slackjaw. 😮
Glad to hear it MD - that kind of stuff is motivating. I appreciate the kind words my friend - have a good weekend :)
Jerry I had to watch this again I enjoyed it so much. Question, are we going to see the finished F-150 project? Finish paint, etc. I bet it looks like new. Take care.
Yes - I'm doing it for a friend in between collision jobs. It should look pretty nice - you take care too Mike 😊
I learn so much from youre videos thank you !!
You're welcome LP - enjoy the week :)
I Like your videos you do the same Type of work as my Late Brother did he made Bench shears from 1/2 inch steel 18inch Long It made the process so much easier They was great for 1/8 sheets keep up the good work ps am from the UK 🇬🇧 AGE 62
Thanks Christopher :)
love this video thank you
You're welcome. The block sanding and painting videos are coming up soon. Thanks for watching FD - happy 🦃
Greetings from Connecticut! Great job, Jerry!
Interesting... How's Connecticut? Never been there. Thanks for watching Joseph :)
@@LakesideAutobody Well, the winter has been unusually mild, so I’m certainly happy about that! Enjoy your channel. Hope you’re doing well!
@@jumpinjojo 👍🛠😊
Nice work.
Thanks WW777 😊✌
Bless Very, very nice video. Thanks 😊
Thanks John - have a good weekend :)
Wow.....nice work. Now, just add a new truck bed to that good piece of metal....lol.
Thanks and thanks for checking it out :)
Dude, I live on the Gulf Coast and we bitch about the salt but you guys and the whole Northeast are on a whole different level! LOL
Good video! Thanks once again!! Phillip Hall
You're welcome Phillip - enjoy the rest of the week :)
good work..thank you!
You're welcome Dave :)
Nice job and a great job with the video!! New to your channel, enjoyed your vid
Thanks Don and welcome... Always feel free to ask ?s - I get to them 1-2 times a day :)
Wow, that was quite a rusty box side. I had one of those trucks in the past, I did not know there was a piece of foam at the top of the arch. Great repair Jerry, maybe you will keep going on that truck ?
Yes PSG - I'm going to keep going till she's all done. It's a friends truck that I do in between other work :)
@@LakesideAutobody awesome !!
Love it thanks again
You're welcome Donald - have a great weekend :)
Good job
Thanks :)
👀 beginning was scary 🔨
another incredible video, thanks for that. what gauge were the sheets you cut and what was that black spray on the metal parts?
The sheet metal is 20 gauge (.035"). The black spray was rubberized undercoating. See this video of a decent method to prevent future rust - kzhead.info/sun/a7yaiqaxbnl5ank/bejne.html
great job, hope you know they do make inner and outer patch panels for them trucks around 50 bucks a piece well worth saving time in making your own especially the inner.
Yes - thanks for the information. Have a good weekend my friend :)
MAN !!!!!! WHER ARE YOU LOCATED!!!! I have all my trucks go 250k miles,sell them n watch them go another 150k’s !! All Chevys !! I had Fords ! Surface rust,Brakes at 60k so I backed away ! GREAT VIDEOS !!
Thanks Terry. I'm in upper Michigan but I just flip cars and trucks. Rust bucket trucks and clean title repairable vehicles. Glad you enjoyed the video my friend :)
Good work
Thanks Tim - have a good weekend :)
Love these rust repair videos, thinking about taking on rusty bedsides on a 09 silverado due to your videos. Since there is exposed metal on the inside and under welds how long will the rust hold back for? Your other video with gluing/bonding the panel has me very interested in trying that as I can see the moisture being held back longer.
As long as you can take care of it - it will last - see this video - kzhead.info/sun/a7yaiqaxbnl5ank/bejne.html You want the inside to drain and stay greasy :)
@Lakeside Autobody I can definitely obsess over keeping it greasy! Maybe I will weld it vs bonding it in that case.
@@Geoff240ti I try to do it on every oil change - see this video for how well it works starting it on a new car - kzhead.info/sun/rJRulLKwq1-kiZs/bejne.html
@Lakeside Autobody I've watched that before a couple of times! I think I could pull the tail lights to oil a bedside repair. By the way.. if you specifically made a video on a 07-13 GM truck bedside repair you'd have hoards of viewers. Bedside panels are often not in stock, and those things rust out so fast.
@@Geoff240ti I actually have a guy that wants one of those fixed. I told him when I catch up, I'll take care of it for him - there are a ton of those trucks out there - rust in the same spots :)
Hi Jerry, Friday comes around, and so do your videos :) Looks awesome. What gauge of metal are you using? Is it a special metal? I've heard of satin coated, whats so special about it. Wonder if you could or have a video, about the sheet metal requirements? Have a great weekend. You definitely earned it!
It's 20 gauge (.030") nothing special - CR sheet I think A1008 from Alro Steel in Grayling, MI. I'll write that down - good idea for a video my friend. You have a good weekend too 😊
satin or also galvanneal are a subtype of galvanized steel that has a...satin appearance among other characteristics. zinc-aluminium-other components coating over steel to sacrifice itself(galvanic corrosion) first before the iron. These coatings don't like heat from welding (arc or flame will burn the zinc alloy) , which is why automakers who use a lot more of it prescribe MIG Brazing, adhesive spot welding and adhesives. Ultra High Tensile Strength Steels also don't like heat from welding.
@@rolfbjorn9937 Thanks for the information and your input Rolf B - where you an engineer?
They’re all worth saving. Have you seen the price of new and used vehicles?
Great Video, looking forward to part II. Rust never sleeps in your part of the world.
You're right Irish G - good to hear from you my friend. Have a good weekend :)
This is great stuff. In your other videos - you are very right about lapping patches instead of butt joints - especially for amateurs like me. On the body filler - my bondo starts to set in less than 2 minutes - before I can really get it how I like it. What products or tips do you suggest to get time for spreading?
Use less and less hardener until you get it to harden when you want. After a while you'll be able to hurry the hardening or slow it down depending on your needs. That's it. Oh... when it's hot out, it's going to harden fast --- cold = slow :)
@mattwarrensocal - is lap joints better than butt joins? Isn't a lap joint a prime spot for moisture to penetrate (and thus be a moisture- trap) and promote the same rust issues?
You're a good teacher. Btw, what welding helmet is that? What do you like about it? Thanks!
To me all welding helmets are very similar - even the cheap harbor freight one works great. YesWelder sent this one out for me to try it so... It works well and has the 180 view that darkens also. Here's one similar (mine's discontinued) kzhead.info/sun/ZLyCmcZ8aZt3oZs/bejne.html Thanks for you kind words too Kevin 😊
Thanks for the class lol can you tell me what kind of metal sheet you use for the job not clue on what to use thanks in advance
20 or 22 gauge CR A1008 Sheet Metal. You can get this stuff from most metal supply places like Alro Steel. 20 gauge is ~ .035" -- 22 gauge is ~ .030"
@@LakesideAutobody thank very much trying to do my own lol
@@victorbeltran5304 Cool - let me know if you have any more ?s :)
Awesome
Hey Jerry what do you think about primer sealer over fill primer I saw a can of automotive primer sealer and it said to spray over last primer coat before painting 🤷♂️
Sealer can be very helpful. Some guys like to use it some don't. It get everything one color, seal the body work, help with covering any very small imperfections, prime any tiny bare metal spots that were missed. :)
@@LakesideAutobody I think I’ll try it hopefully it won’t rain Saturday 😁
@@sheerwillsurvival2064 👍
What gauge sheet metal do you use for your patch panels? Thank You for the great video.
22 or 20 - 22 ~ .030" & 20 ~ .035" Both hold up well over time and can be worked with easily :)
I'm about to try welding a patch panel for the first time. What gauge sheet metal do you recommend using for around the wheel well area and the side sill?
22 or 20 gauge 22 is ~.030" and 20 is ~ .035"
All these quarter-panel/arch/inner arch issues come from above - seals that leak around the screens/boots/etc etc & let water down inside the panels. Always. Keep an eye on your seals.. Stuff like this I no longer bother making up panels - I toddle along to a scrapyard & chop a better section out of one of their vehicles, weld that better section onto the car I am repairing. Cut your "donor" panel good & big - trim it to fit when you get home. Just glancing at the chassis, that vehicle is toast anyway unless the entire chassis gets a treatment pretty swiftly. I have yet to come across any proprietary treatment that works, so I made my own that does. All that aside - excellent instructional video LSA - as per usual. Practical, to the point & real-world stuff.
My "last" comment would be, when done, drown the whole repair in epoxy 2k primer - if you don't, it will rust again in no time. I have found no substitute for epoxy 2k primer. Every other form of primer is a waste of time & energy. It will rust again in jig time. Plus, use flux-core. Flux core works better for bodywork. It just does.
Thanks for your input James - have a great week 🛠👍😊
good job
Thanks 🛠👍
How does the Arccaptain compare to the YesWelder you had in earlier vids? Do you still use that one too? Nice project!
I only use the ARCCAPTAIN now - it welds really nice and is super user friendly. Has a nice big interface with large letters and number for older eyes 😊 They both weld very similar - I've been pretty impressed with the import welders. Getting parts may be a different story if you ever need them 🥴
Have you got any videos recommending how to handle rusted out windshield frames? My 2000 Mustang has some amount of rust beneath the windshield (havent removed it yet, is an absolute hassle, but used a 9 gauge guitar string to remove the windshield on my subaru just fine, havent tried it yet on the Mustang), and on my Subaru, in the wall that goes from the windshield flange up to the roof, theres an area where it has rusted all the way through. Having watched a lot of your vids over the last couple years, I feel like I can piece together a solution, just wasnt sure if there was a more definitive solution.
You can absolutely fix all of that - had a Ranger that rusted through the windshield and down the fire wall. The metal cowl (grille) had to be cut out, the repair done and painted inside the air duct/ cowl area, then the grille part welded back in and mudded up. It took some time but it can be fixed. You can do it how ever you can do it - it that makes sense :)
Would a complete bedside be a better route to go with that much rust? Where do you draw the line on something like this?
Money draws the line. The cheapest route is homemade patch, then patch panels then bedside then whole bed :)
You are a true genius and great metal sculptor, and you can work on my vehicle anytime!
Thanks for the support Ben - I appreciate the comment. Happy New Year 🎉😊
what gauge of sheet metal are you using?
20 gauge ~ .035" or 22 gauge ~ .030"
PS surely the customer told you to treat hole car with Evaporust and a good body sealer knowing it's only done 65.000
I'm so old I can remember when we had actual body shops in this country
Yep - I think rust repair was common back then. Not now though :(
how long will the ford f 150 aluminum body last? are they collision repairable? thanks!
I have one right now and I'm sure the body will last a very long time but one thing to remember is that the underbody, frame, fuel lines, brake lines, brackets, mounts, etc. are all steel and will rust so.... They are collision repairable :)
@@LakesideAutobody how old is your ford? it would be great if you would do a review of how the aluminum body and paint on aluminum is holding up.
Hi there. Happy Wednesday to ya. IF you feel like answering an unrelated question, I've got one for ya- I have an old super surface rusty hood that I am going to practice on. It seems though that the metal has become thin because of the ridiculous amount of flex in it. Can filler flex like that? It will definitely need some areas knocked down and filled, and skim coated. Will all that material flex with the metal? -DIO
It was sort of common that old large hoods flexed quite a bit. If it's just flexing that's fine. If it is "popping" in and out you'll have to address that. One way to fix it is this - kzhead.info/sun/fpmGhrqmqneIpJs/bejne.html
What is the tool you used to cut the sheet ive never seen one?
They don't sell that one anymore but Harbor Freight does sell this now - www.harborfreight.com/power-tools/power-saws/metal-shears/5-amp-14-gauge-metal-shears-64609.html
@@LakesideAutobody thank you
👍@@samwhite1345
I did this on my pickup but it was worse so i built a wheelhouse out of 16 gauge and then I finished with parts of a hood. It took me a very long time and I'm wondering how long did you spend on this project?
Generally a patch like this takes about 4 hours. If you started at 8am you should have the thing in primer before lunch. Go to lunch, come back and block sand it. That's how it went working in a body shop many times. Feather fill and lacquer primer with both dry nicely while your at lunch about an hour @ 70 degrees
jerry, if the frame on that vehicle sound or is it rusted badly and dangerous? Are you going to fix the frame also?
The frame on this is crusty but very solid. I have fixed frames before though - I'd like to do a video on that one day too 😊
Damn good job. Do you offer services to the public?
Unfortunately, I just make YT videos. I flip clean title, repairable vehicles for collision videos and rust repair is done on family vehicles. Even with doing close family member rust buckets, I'm booked for months out! Thanks for asking though MP800 :)
What gauge metal? Made that look EASY!
20 gauge (.035") A1008 CR Sheet Metal from Alro Steel in Grayling, MI