How To Repair Sheet Metal Door Rust

Ideal for loot rooms and other cramped areas.

How to repair sheet metal door rust.

I used a piece of pvc pipe a vice mount miniature metal break and body hammer kit. Thoroughly mix equal parts of the two part epoxy putty. Scrub partially rusted metal areas with a wire brush to remove flakes and powdery surface rust then prime with a rust inhibitive primer. 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.

Sheet metal door the sheet metal door is the most common door found on bases due to its resistances to melee weapons and fire but relatively cheap cost to craft. It requires double the materials but allows for more space within your base. Once done you can paint over rust. 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.

The complexity of welding increases as the thickness of the material decreases. Regardless it is still relatively weak to explosives compared to its expensive indirect upgrade the armoured door. However badly rusted metal areas need more prep work and possibly a special primer. The most permanent repair to a hole in sheet metal is to weld the hole shut.

If the repair area is large you may need to mix the two part epoxy in stages to allow you time to apply the epoxy putty before it hardens. Switch to 120 grit sandpaper to feather the edges of the repair area. Sand through the rust spots down to bare metal. You need to mix enough two part epoxy putty to cover an area at least twice as large as the rust you need to repair.

Complete the feathering with 220 grit. A clear primer is left on the bl. Rust doctor is a latex water based product that converts rust to a non rusting black iron oxide that will never rust again. Start with a wire brush photo 1.

I then used the templates to trace out the patch panels on some sheet metal. Specially formulated metal primers are designed to help prevent future.