The average car owner can do basic body work on a Jeep with rust holes. Most homes have the tools needed, and the rest can be bought at an auto parts store. Use a kit that creates a hard fiberglass shell over the hole; it is impervious to rust because it is a poly-fiber. Using this kit and some tools around the house, you can get started.
Instructions
1. Cut away as much of the rust as possible, using metal snips. Avoid cutting good metal.
2. Grind the entire area of the hole using a power grinder about three or four inches from the hole. Do not scrap off too much paint. Grind only until you see shiny metal. Round the edges by bending them back, gently tapping them with a hammer until they go to the inside of the hole.
3. Use 100-grit sandpaper to feather the metal to the paint. This will help hide any sign of body work.
4. Place the release film that comes in the kit over the hole. Cut the release film with scissors. Cut it three or four inches larger than the hole, as it also will cover the fiberglass.
5. Lay the cut release film on a flat surface, and place a sheet of fiberglass over it. Cut a portion of fiberglass an inch smaller than the release film. Place a second sheet of fiberglass over the first piece, and cut it one inch smaller than the previous piece.
6. Mix the fiberglass and the hardener that come with the kit. Work quickly so it does not harden before you finish. Place the release film over an old flat board, and place the larger piece of fiberglass on top. Apply the mixture you just made to the fiberglass using one of the spreaders. Do not allow it to dry. Place the second piece of fiberglass over the first, and apply the mixture again.
7. Take the section you just created, and cover the hole with the fiberglass. Make sure all the bubbles are removed so no bubbles are in the final product. Smooth it with your hand or a flat edge.
8. Allow the patch to dry. The time will vary depending on temperature. Once it is dry, peel an edge of the release film slowly so you do not disturb the patch.
9. Mix a small amount of body putty and body putty hardener, and apply it to the edges of the patch. It will harden quickly. After it has hardened, sand it with 80-grit sandpaper. Make sure it is smooth to the original surface of the vehicle. On areas raised higher, use the file.
10. Mix another batch of the body putty, and apply it with one of the spreaders in an even coat. Allow it to dry, and sand it until it is smooth using 400-grit sandpaper; this will give you the best feel as to the smoothness and evenness of the work.
Tags: release film, body putty, fiberglass over, piece fiberglass, body work, fiberglass over first
