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This page shows "One" way  how to repair rust bubbling on a car at home without a welder. Tools required are a grinding wheel and goggles, tin snips, a drill, Duraglas and spreader, pop rivets, a grinder sanding blocks and sandpaper 40, 80 and 120 grit and a small hammer.

Rust Repair

Poorly repaired rust project. Bubbling up because of moisture and rust decaying old body filler. also old damage looks like some kind of dent (hard to tell on this photo)

Rust Repair

Poorly repaired rust project. Bubbling up because of moisture and rust decaying old body filler. also old damage looks like some kind of dent (hard to tell on this photo)

Rust Repair

Poorly repaired rust project. Bubbling up because of moisture and rust decaying old body filler. also old damage looks like some kind of dent (hard to tell on this photo)

Rust Repair

Clean all old body filler and rust off

Rust Repair

remove all paint and body filler

Rust Repair

remove all paint and body filler

Rust Repair

remove all paint and body filler

Rust Repair

remove all paint and body filler

Rust Repair

Cut a piece of steel the size you need

Rust Repair

Dry fit piece to check fit

Rust Repair

Drill holes, 2 at first to align piece then when all's straight drill the rest of the holes. (use pop rivets to hold piece on pannel)

Rust Repair

Tap area down if you need to and grind off any high spots

Rust Repair

Tap area down if you need to and grind off any high spots

Rust Repair

Use a good fiberglass filler like Duraglas

Rust Repair

Clean and mask off everything and spread duraglas over the area evenly

Rust Repair

sand down with the proper size block useing 40 grit to start then switch to 80 or 100 grit to finish body work

Rust Repair

Tap area down if you need to and grind off any high spots

Rust Repair

Clean and mask off everything and spread duraglas over the area evenly

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