Repair of rusted holes and punctures (Opel Frontera A)

1. Using a sanding or wire bit clamped into the chuck of an electric drill, remove all traces of paint from the damaged area and an area about 3 cm wide around it. If it is not possible to use an electric drill, the work can be done just as effectively by hand using sandpaper.

2. After removing the paint, you can assess the extent of metal damage from corrosion and decide whether it makes sense to start repairs or whether it would be wiser to replace the entire panel (if this is possible in principle). New panels can be purchased for not nearly as much as many car enthusiasts think. It is often much faster and even more economical to install a new panel than to repair extensive damage to the body.

3. Remove all body trim elements from the damaged panel, except those that can serve as a guide for recreating the original shape of the deformed areas (such as headlight trim, etc.).

4. Using tin snips or a hacksaw blade, remove any loose, weak or hopelessly corroded pieces of metal, then hammer the edges of the hole inward to create a recess for the filler material to sit in.

5. Use a wire brush to remove powdery rust from the damaged metal.

6. If the back of the damaged area is accessible, treat it with a corrosion inhibitor.

Text copied from this portal: OPELBOOK.ru

7. Before starting to putty, the hole must be sealed. This can be done by riveting or screwing a piece of sheet metal to the back of the damaged area, or by covering the hole with wire mesh.

8. After blocking the hole, the damaged area can be filled and painted (see Puttying and painting).