13 Simple Steps to Fix Your Car's Corrosion and Rust

Over many years' time and constant exposure to rain, sleet, snow and ice a car or truck's body panels can begin to suffer from corrosion and eventually may become punctured. Of course these punctures or holes can really look ugly and lower the value of your car at resale, as well as possibly cause the actual car structure to weaken.

Before this happens there is a product that you should use that will repair the holes, stop the corrosion and help you restore the body panels to like-new condition.

Bondo is the name of that product, and Bondo putty can serve as the filler you need to repair the holes and form a nice, tight new seal over any of your car or trucks damaged panel areas. Bondo putty is usually sold as a 'kit' with the supplies and basic tools you need to accomplish small repairs. However, if you want a finished product that looks like an expert did it, you should follow the procedure below:

First, before starting any car or truck repair job, thoroughly wash the vehicle and get all your tools and supplies ready.

Mark the damaged area with a thick marker, allowing extra space for rust or other damage that has weakened the metal.

Using a 'rat tail' file bore into the edges of the hole using back and forth strokes along the entire perimeter. Grind down the rusted areas until you have reached good, solid metal, removing all the rusted or corroded areas completely.

Nest, attach a wire brush wheel to your power drill and sand the marked area until you reach bare metal, leaving no paint behind in the area you marked earlier. When finished wipe the area completely with some paint thinner on a soft rag to remove any grease or oil.

If the area to be repaired is small cover it from the inside with a piece of duct-tape making sure it adheres well. For larger holes or areas cut a patch using wire screen that is large enough to cover the hole, overlapping it at least two inches.

Next mix the Bondo putty as directed.

Apply a thick layer of putty to the underside edges around the damaged area using the spatula supplied with the Bondo. For smaller holes, smooth it nicely into the hole and feather outwards onto the metal. For larger areas, center the screen over the hole and use the spatula to smooth in the Bondo over the screen and then feather. Allow the putty to dry according to the directions.

Once dried, mix some more Bondo and apply a thin layer over the screen on the underside of the body panel. Let the putty dry according to directions.

With your third Bondo application apply a thick layer in an outward, fan-like motion using the supplied squeegee. You want a layer thick enough that it is higher than the surrounding metal. Let dry.

With a sanding block and 200 grit sandpaper, sand the putty in a circular motion, leaving some putty above the metal surface.

Using 400 grit paper, you next want to sand completely down to the good metal around the damaged area, using smooth motions and delicate force. You can switch to 1000 grit if you choose and the finish will be even better. Change your sandpaper when it clogs.

It's possible, if this is your first time using Bondo and repairing a body panel, that your first try might not produce the results you desire. If that is the case just mix up a little more Bondo, smooth it on, let it dry and try sanding it down again.