Basic car metal repair with welding
by Patryk Rebisz

Don't be intimidated by welding as the job is easier then one might imagine. Welding is a process of fusing metal together by using high heat to melt parts together. If done correctly it produces extremely strong bond but because it involves powerful forces of heat produced by electricity, it can be a bit intimidating to a novice. Though sometimes rust can be fixed with fiberglass, there are times when for structural purposes there is no other way than to use metal.

The metal around front right seat support rusted out and this small repair job can be used to explain the steps. Because the support bracket is meant to support the seat, fiberglass repair wasn't an option.

To do the job you need a welder, protective gloves, a mask and a hammer with a point to chip off molted metal overspray. Besides, you also need tools to prep the surface and cut/shape the metal.

1. The problem.

2. Assess the damage. Chip away as much rust as you can to the the extend of rust (it's ALWAYS more than anticipated).

3. Cut out the rusted metal that's too thin to weld to and strip paint around the welding edges.

4.Create a template from cardboard for the metal patch; cut and shape the metal patch.

5. Using magnets or temporary metal screws secure the patch to the area then attach ground from your MIG welder to bare metal area. Place the tip with electrode where you want to apply the weld then squeeze its trigger (protecting the eyes from brightness and hands from splatter). Spot weld a few corners to secure the patch in place. Basic welders have very few options - usually it's strength of the electrical current and speed with which the electrode unwinds each time you squeeze the trigger. It's that simple. With some practice you should master the basics in no time.

6. Keep on spot welding avoiding prolonged bead of weld to prevent metal deformation.Try to spot away from one naother giving ample time between for material to cool off. When the patch is welded on all sides, grainde off the welds for smooth surface.

7. Protect the surface of the new metal by painting with some sort of "paint over rust" or "paint with primer." If you don't have access to back of the patch drill access holes and spray wax or rust preventer then seal the access holes with rubber plugs (not pictured).

8. For extra weather protection, you might seal the edges with car sealant. Do that especially on the seams facing the outside. Painted and sealed, you shall spray some sort of chip-guard on the outside to prevent the paint from flaking off as the undercarriage is hit by small rocks and road debris.

Done!