Cody Casey
Rust on cars is inevitable, but if you deal with it early, you can stop it from spreading. Fixing a rust hole in your car requires first removing the rust and any affected metal, and then filling the hole. You can use a wire brush attachment on your drill to remove the paint and rust around the hole. Then, cut away the affected metal with a grinder or tin snips. Once you’ve cut away the metal, cover the hole with a piece of wax paper and apply a mixture of fibreglass filler and hardener. You can also use polyester resin and glass fibre pads to fill the hole. After the filler has dried, you can sand down the patch to remove any imperfections. Finally, you can apply a coat of touch-up paint to match your vehicle.
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What You'll Learn
Remove the tail panel from the trunk gutters
To remove the tail panel from the trunk gutters of a 1970 'Cuda, you must first gain access to it by removing the trunk floor. The trunk floor cannot be removed with the tail panel in place, so the first step is to free the tail panel from the trunk gutters.
The tail panel attaches just in front of an upward lip at the rear of the trunk floor. To remove the tail panel, you can cut the floor just in front of the upward lip. If you plan to reuse the tail panel, it is much easier to remove the remaining floor from it on the bench.
To separate the two, you can start by cutting out the centre of the floor between the frame rails. Before that, the pair of trunk floor braces will need to be cut loose from the rear crossmember so that the braces can come out with the floor. With the centre of the floor out of the way, you will be able to access the rest of the floor much more easily.
You can then begin to peel the remaining floor off of the frame rails, but this will require breaking quite a number of spot welds. If the part being removed is not going to be saved, you may find that a 3M belt rile is faster and easier to work with in tight spaces than a Rotabroach cutter.
As an alternative to cutting out the trunk floor, you could also try to remove the tail panel by cutting it out and then pulling the replacement panel into position from the trunk. However, this may require cutting off the gutter strips so that they can fit underneath the new tail panel.
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Cut out the rust and weld in patches
Repairing rust damage on a car can be a daunting task, but it is a rewarding process that can breathe new life into your vehicle. Here is a step-by-step guide to cutting out the rust and welding in patches to repair a rust hole in the trunk pan of your 'Cuda:
Identify the Rusted Area
Before you begin, it is crucial to assess the extent of the damage. Identify and mark the rusted area on the trunk pan. Understanding the scope of the damage will help you determine the tools and materials needed for the repair.
Cut Out the Rusted Area
Using a cut-off wheel or a vibrating cutting tool, carefully cut away the rusted metal. Ensure that you only remove the affected metal, being cautious not to compromise the underlying structure or surrounding areas. This step requires precision, as each cut is crucial to a successful repair.
Prepare the Patch
Choose a replacement patch panel with the appropriate metal thickness. It should be slightly thicker than the original metal to provide strength and durability. Cut the patch panel to size, allowing a little extra room as it can be ground down to fit perfectly later. Shape the patch to seamlessly fit the contours of the trunk pan.
Weld the Patch
With the patch ready, it's time to weld it into place. Use a weld-through primer to protect the underlying metal and prevent future rust. Weld the patch securely, ensuring a seamless weld that blends the new metal with the old. The stitch welding method can be useful for long panels, as it reduces warpage by first making spot welds and then adding short stitch welds.
Grind and Smooth the Welds
After welding, use a grinder to smooth out the welds and ensure a flush finish. Take your time with this step, as it will impact the overall appearance and quality of the repair. A flap-wheel disc is recommended for faster grinding that generates less heat on the metal.
Final Steps
With the patch welded and smoothed, your trunk pan should now be free of rust holes. You can finish the repair by painting the patched area to match the surrounding surface. Additionally, consider applying protective coatings to prevent future rust and maintain the integrity of your 'Cuda.
Remember, practicing on less visible areas or smaller rust holes can help you refine your technique before tackling more complex repairs. With the right tools, patience, and attention to detail, you can achieve a seamless and long-lasting repair.
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Apply a fibreglass filler and hardener
When applying fibreglass filler and hardener to repair a rust hole in a trunk pan on a 'Cuda, it is important to follow the correct steps to ensure a strong and durable repair. Firstly, prepare the surface by removing any old rust and paint from the area using an angle grinder with a flapper wheel. This will ensure that the filler adheres properly to the surface. Before applying the fibreglass filler, it is crucial to mix it with the hardener in the correct ratio as specified on the product's instructions. The mixture should be prepared on a surface that does not soak in the resins, such as wax paper over cardboard.
When applying the fibreglass filler, use a plastic applicator to spread the mixture onto the surface. Ensure that the thickness of the filler does not exceed 1/16 of an inch or 1.5 mm. The filler should be applied smoothly and evenly, dragging the filler across the surface to avoid introducing air bubbles. If necessary, apply additional filler to ensure complete coverage of the repair area. The filler will have a limited work time, after which it will become difficult to work with and may not bond as effectively.
Once the filler has been applied, allow it to dry thoroughly. The drying time will depend on the amount of hardener mixed into the filler and the weather conditions. Generally, the filler should be left to dry for a few hours, or preferably overnight, before proceeding to the next step. After the filler has dried, use 80-grit sandpaper to block the surface and shape the repair. This process may require patience and a careful eye, especially for those new to bodywork repairs.
To ensure a smooth finish, use 220-grit sandpaper to block the surface, working across the panel to avoid creating waves in the filler. If necessary, apply a guide coat to help identify any low spots that need further attention. After sanding, the edges between the old paint and the repair area should be feathered to create a seamless transition. If any pinholes or low spots remain, they can be filled using a spot putty, also known as glazing or finishing putty. A two-part product that includes both a filler and hardener is recommended for best results.
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Sand down the patch to remove imperfections
When repairing a rust hole in your trunk pan, you will need to sand down the patch to remove imperfections. This is a crucial step in achieving a smooth and consistent finish. Here is a detailed guide on how to do it:
First, ensure that you are wearing the appropriate personal protective equipment, including eyewear, gloves, hearing protection, and respiratory protection. Sanding can generate a lot of dust and debris, so it is important to safeguard yourself from these particles.
Begin by cleaning the repair area and removing any loose paint particles or rust. Use coarse sandpaper or a file to work down the lead, and don't be afraid to use power tools to speed up the process. Remember to protect your lungs if you opt for power tools.
Once the area is prepared, use a DA sanding machine with an abrasive disc, such as the 3M™ Cubitron™ II Net Abrasive Disc 120+ -150+, to sand down to bare, clean metal. This step will create the ideal surface for applying body filler.
Next, switch to a finer abrasive disc, such as the 3M™ Cubitron™ II Net Abrasive Disc 220+ - 240+, to refine previous sanding scratches. This step is important to prevent solvents from the body filler from penetrating the OEM paint layers, which can cause surface swelling.
After applying the body filler, use the 3M™ Cubitron™ II Net Abrasive Disc 320+ to refine the edges of the repair area. It is recommended to use a soft interface pad when sanding curved areas to achieve a consistent finish.
Finally, identify and address any remaining sanding scratches by applying a 3M™ Dry Guide Coat. This product will help ensure that imperfections and sanding marks from previous steps have been fully removed, resulting in a high-quality repair.
Remember to take your time during the sanding process and work in a well-ventilated area to ensure your safety and the best possible outcome for your repair.
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Spray on a rust inhibitor
To repair a rust hole in the trunk pan of a 1970 'Cuda, you will need to remove the trunk floor. The first step is to free the tail panel from the trunk gutters. Then, cut the floor just in front of the upward lip at the rear of the trunk floor, where the tail panel attaches.
Once the tail panel is removed, you can cut out the center of the floor between the framerails. This will give you better access to the rest of the floor. You will need to break the spot welds to peel the remaining floor off the framerails.
Now, you can spray on a rust inhibitor to protect the exposed areas from future rust. Rust-Oleum Stops Rust is a clear spray inhibitor that can be used on bare metal surfaces for indoor or outdoor items. Alternatively, Fluid Film is a popular anti-rust spray that can be used on bare metal car bodies.
After applying the rust inhibitor, you can proceed with welding in patches or installing a new trunk floor.
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Frequently asked questions
To repair a rust hole in the trunk pan of a 'Cuda, you must first remove the rust and any affected metal, and then fill the hole with a fibreglass body filler. You can use tin snips or a grinder to cut away the affected metal. Once the hole is filled, you can paint over it to match the rest of the car.
You will need a wire brush, tin snips or a grinder, a rust inhibitor, wax paper, a mixture of fibreglass filler and hardener, sandpaper, and automotive paint.
The first step is to remove the paint and rust around the hole. You can use a wire brush attachment on your drill to remove the paint, and then use tin snips or a grinder to cut away the rusted metal.
After repairing the hole with fibreglass body filler and sanding down any imperfections, you can apply a rust inhibitor to the area to help prevent future rusting. You can also spray the repaired area with automotive paint that matches your vehicle to help protect it from the elements.
