Custom Patch Panel Tutorial | Rust Repair for Beginners
Got a rusty car or truck? Don’t worry—today I’ll show you how to make a custom patch panel from scratch, even if you’re a beginner with just basic tools. This video focuses on restoring the inner rocker area, but the techniques work for any metal panel repair, whether it’s a door, floor, or fender.
🔧 Recommended Tools & Supplies
(The links below are Amazon affiliate links. If you use them, it helps support the channel at no extra cost to you.)
👉 Eastwood Throatless Shear Multiple Purpose Bench (Great for Cutting 16ga and Up!)
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👉 Eastwood 140 Amp 120V MIG Welder Machine for Sheet Metal (Welder I Use)
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👉 Blue Demon .023 X 2 LB MIG/GMAW Carbon Steel Welding Wire (Wire I Use)
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👉 3" Quick Change Easy Strip Discs for Drill 11 Pack (Removes Rust Easily)
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👉 Heavy Duty Automatic Center Punch (No Drill Bit Wander)
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👉 Eastwood Organic Binders Self Etching Weld Thru Gray Aerosol Primer (Prevent Rust)
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👉 Movable Welding Table,36"x18" (Makes Welding More Comfortable)
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👉 Eastwood Electric Mini Belt Sander (Weld Removal)
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👉 ARCCAPTAIN Welding Magnets 25LB&55LB 4Pcs (Weld Prep)
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Timestamps
0:00 – Intro: Making a custom patch panel
0:29 – Checking metal thickness & deciding gauge
1:05 – Making the template (tape, cardboard, or paper)
1:58 – Marking and referencing the patch
2:27 – Making multiple templates for complex patches
3:01 – Transferring templates to metal
3:18 – Cutting the metal: shear or tin snips
3:30 – Cleaning metal for prep
4:29 – Noting spot welds & backside gaps
4:50 – Removing old metal
5:29 – Fitting and bending new metal
6:04 – Ensuring proper fit before welding
6:25 – Tack welding the patch
7:14 – Welding technique & spreading heat
7:40 – Handling big gaps with copper backing plate
8:04 – Grinding welds for clean fit
8:36 – Final test fit & gap checking
8:50 – Applying weld-through primer
9:00 – Drilling plug weld holes
9:11 – Welding the patch in place
10:09 – Grinding and final adjustments
10:28 – Final thoughts & beginner tips
⚠️ Disclaimer
This video is for informational and entertainment purposes only. I am not a licensed or certified professional. The methods shown may not be appropriate for every vehicle or situation. By attempting any work shown in this video, you assume all risks associated with it. Always follow manufacturer guidelines, use proper tools and safety equipment, and consult a qualified professional if necessary.
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